Fuel Injector -- Removal |
- NOTICE:
- When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.
- When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.
- After removing the injection pipes, clean them with a brush and compressed air.
| 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- CAUTION:
- Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
- NOTICE:
- When disconnecting the cable, systems need to be initialized after the cable is reconnected (Toyota Fortuner RM000002HD2005X.html).
| 2. REMOVE INTERCOOLER ASSEMBLY |
| 3. CHECK FOR INJECTOR COMPENSATION CODE |
- HINT:
- If the injector compensation code is not correctly registered, it may cause malfunctions.
Read the injector compensation code (Toyota Fortuner RM0000012XK030X_02_0003.html).
Check that compensation code of installed injector is same as code registered in ECM. If the code is not as specified, register the injector compensation code on the injector (Toyota Fortuner RM0000012XK030X.html).
| 4. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY |
- NOTICE:
- After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
Remove the bolt and No. 2 injection pipe clamp.
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Remove the 2 nuts and No. 3 injection pipe clamp.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
| 5. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the 2 bolts and disconnect the 2 injection pipe clamps.
- NOTICE:
- If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
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| 6. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
Disconnect the 3 fuel hoses.
Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.
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| 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY |
Remove the 3 bolts and disconnect the 4 connectors.
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Disconnect the ventilation hose.
Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.
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Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
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| 8. REMOVE INJECTOR ASSEMBLY |
Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.
- NOTICE:
- When removing the nozzle leakage pipe, place a cushion under the pipe.
- Be careful not to deform or scratch the union seal surface.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
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Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.
- HINT:
- Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.
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Remove the O-ring from each injector.
Remove the 4 injection nozzle seats from the cylinder head.