REMOVAL AND INSTALLATION


Pre-removal Operation
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Intercooler Air Hose B Removal (Refer to GROUP 15 - Intercooler ).
  • Air Intake Pipe Removal (Refer to GROUP 15 - Inlet, Exhaust Manifold and Turbocharger ).
  • A/T Fluid Level Gauge and Guide Assembly Removal (Refer to GROUP 11E - Camshaft ) <A/T>.
  • Engine Oil Level Gauge and Guide Assembly Removal (Refer to GROUP 11E - Camshaft ).

 Post-installation Operation
  • Engine Oil Level Gauge and Guide Assembly Installation (Refer to GROUP 11E - Camshaft ).
  • A/T Fluid Level Gauge and Guide Assembly Installation (Refer to GROUP 11E - Camshaft ) <A/T>.
  • Air Intake Pipe Installation (Refer to GROUP 15 - Inlet, Exhaust Manifold and Turbocharger ).
  • Intercooler Air Hose B Installation (Refer to GROUP 15 - Intercooler ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Fuel Line Air-bleeding (Refer to ).




Removal steps


1.
 Battery cable connection


2.
 Control wiring harness connection


3.
 Harness bracket assembly


4.
 Injection pipe clamp
<<A>>
 >>B<<
 5.
 Fuel injection pipe


6.
 Fuel return hose connection
<<B>>
7.
 Nut
<<B>>
8.
 Fuel return pipe


9.
 Fuel return pipe gasket
<<C>>
10.
 Fuel injection nozzle assembly

>>A<<
 11.
 Holder gasket

>>A<<
 12.
 Nozzle gasket

REMOVAL SERVICE POINTS

<<A>> FUEL INJECTION PIPE REMOVAL

When loosening the nuts at both ends of fuel injection pipe, hold the delivery holder (for fuel injection pump side) and the fuel injection nozzle (for fuel injection nozzle side) with a wrench and loosen the nuts.

<<B>> NUT/FUEL RETURN PIPE REMOVAL

1.
caution If an attempt is made to loosen the nut without first holding the fuel return pipe, the fuel return pipe may be broken or otherwise damaged.
While using a spanner or similar tool to hold the hexagonal nut of the fuel return pipe, remove the nut.
2.Disconnect the fuel return pipe.

<<C>> FUEL INJECTION NOZZLE ASSEMBLY REMOVAL
caution
  • Make a mark on the removed fuel injection nozzle assembly (the cylinder number).
  • Use a cap to prevent foreign material, etc. from entering the fuel injection nozzle hole.

Using a deep socket wrench, remove the fuel injection nozzle assembly.

INSTALLATION SERVICE POINTS

>>A<< NOZZLE GASKET/HOLDER GASKET INSTALLATION

Clean the cylinder head’s fuel injection nozzle hole, and insert a new gasket.

>>B<< FUEL INJECTION PIPE INSTALLATION

When tightening the nuts at both ends of fuel injection pipe, hold the delivery holder (for fuel injection pump side) and the fuel injection nozzle (for fuel injection nozzle side) with a wrench in the same manner as removal, and tighten the nuts to the specified torque.
Tightening torque: 23 N·m