Injector removal (4JJ3 without DPD)

1. Component views

Injector

Part name

  1. Leak-off hose
  2. Injector clamp
  3. Injector clamp bolt
  4. Clip
  5. Injector
  6. Gasket
  7. O-ring
  8. Pin
  9. Injection pipe (Injector side)
  10. Common rail (fuel rail)
  11. Injection pipe (common rail (fuel rail) side)
  12. Clip
  13. Fuel supply pump

Tightening torque

3: 26 N・m { 2.7 kgf・m / 19 lb・ft }

9: 44 N・m { 4.5 kgf・m / 32 lb・ft }

11: 44 N・m { 4.5 kgf・m / 32 lb・ft }

12: 8 N・m { 0.8 kgf・m / 71 lb・in }

3. Leak-off pipe removal

1) Remove the harness bracket from the inlet manifold.

Legend

  1. Harness bracket

2) Disconnect the 3 vacuum hoses from the vacuum pipe.

3) Disconnect the 2 leak-off hoses from the leak-off pipe.

4) Remove the leak-off pipe from the inlet manifold.

Legend

  1. Leak-off hose (Injector side)
  2. Leak-off pipe
  3. Leak-off hose (Supply pump side)
  4. Vacuum hose (Swirl control valve side)
  5. Vacuum hose (Vacuum pump side)

4. Injection pipe removal

1) Remove the clip from the injection pipe.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution

  • Do not reuse the injection pipe.

Legend

  1. Injection pipe
  2. Clip

5. Injector removal

1) Remove the injector clamp from the injector.

2) Remove the injector from the cylinder head.

Note

  • If it is difficult to remove the injector, use a remover.
  • Store the removed injectors with the cylinder numbers attached.

Caution

  • Cover the exposed portion to prevent foreign material from getting into the fuel system.
  • Do not damage the injector nozzle.
  • Absolutely never touch the injector solenoids because that can hinder their performance or cause damage.

3) Remove the gasket from the injector.

4) Remove the O-ring from the injector.

Caution

  • Do not reuse the following parts.
  • Clip
  • O-ring
  • Gasket

Legend

  1. Injector
  2. Leak-off pipe
  3. Clip
  4. O-ring
  5. Gasket