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 |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Toyota Fortuner RM000004W63000X.html).
| 2. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
| 3. CHECK INJECTOR COMPENSATION CODE |
- HINT:
- If the injector compensation code is not correctly registered, it may cause malfunctions.
Read the injector compensation code (Toyota Fortuner RM0000012XK04AX_02_0003.html).
Check that the compensation code of the installed injector is the same as the code registered in the ECM. If the code is the same, register the injector compensation code on the injector (Toyota Fortuner RM0000012XK04AX.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 2 nuts and No. 3 injection pipe clamp.
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Remove the 2 bolts and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Text in Illustration *a Injector Side *b Common Rail Side
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| 5. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET |
Remove the 3 bolts and No. 2 intake air connector bracket.
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| 6. DISCONNECT NO. 3 WATER BY-PASS PIPE |
Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.
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| 7. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (for EGR) |
Disconnect the 2 connectors.
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Disconnect the 6 vacuum hoses.
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Remove the bolt and No. 1 gas filter with gas filter bracket.
Remove the 2 bolts and electric vacuum regulating valve.
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| 8. REMOVE NO. 2 INTAKE AIR CONNECTOR |
Remove the 3 nuts, No. 2 intake air connector and gasket.
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| 9. REMOVE INTAKE AIR CONNECTOR |
Remove the 3 bolts, intake air connector and 2 gaskets.
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| 10. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY |
Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.
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| 11. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the bolt and disconnect the injection pipe clamp.
- 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.
Text in Illustration *a Injector Side *b Common Rail Side
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| 12. 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.
Text in Illustration *1 Union Bolt
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| 13. 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 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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| 14. REMOVE INJECTOR ASSEMBLY |
Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.
Text in Illustration *1 Union Bolt - 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.