Fuel Injector (W/ Glow Plug Controller) -- 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 and fuel inlet pipe, clean them with a brush and compressed air.
| 1. PRECAUTION |
- NOTICE:
- After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (HILUX_TGN26 RM000004QR1006X.html).
| 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3009X.html).
| 3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER |
| 4. CHECK INJECTOR COMPENSATION CODE (for DPF) |
- HINT:
- If the injector compensation code is not correctly registered, it may cause malfunctions.
Read the injector compensation code (HILUX_TGN26 RM0000012XK058X_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 not the same, register the injector compensation code on the injector (HILUX_TGN26 RM0000012XK058X.html).
| 5. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the bolt, nut 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. 4 injection pipe.
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| 6. REMOVE WIRING HARNESS CLAMP BRACKET |
Detach the wire harness clamp.
Text in Illustration *1 Wiring Harness Clamp Bracket
 |
Remove the bolt and wiring harness clamp bracket.
| 7. REMOVE NO. 2 FUEL PIPE |
for DPF:
Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.
Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.
Text in Illustration 
Bolt 
Supply Pump Hollow Screw 
Fuel Check Valve 
Union Bolt Remove the fuel check valve, union bolt and 2 gaskets.
Remove the 3 bolts and No. 2 fuel pipe.
for i-ART:
Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.
Text in Illustration Supply Pump Hollow Screw Fuel Check Valve Remove the fuel check valve, No. 2 fuel pipe and gasket.
| 8. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for DPF) |
Remove the screw and No. 1 vacuum switching valve.
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| 9. REMOVE NO. 3 NOZZLE LEAKAGE PIPE |
Disconnect the 3 fuel hoses.
Text in Illustration Fuel Check Valve
 |
Remove the 2 bolts.
Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.
| 10. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
for DPF:
Remove the 2 bolts.
Text in Illustration *A for DPF *B for i-ART Union Bolt - -
for i-ART:
Remove the 3 bolts.
Remove the union bolt, gasket and No. 2 nozzle leakage pipe.
| 11. REMOVE WIRING HARNESS CLAMP BRACKET (for i-ART) |
Detach the 6 wire harness clamps.
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Remove the 3 bolts and 2 wiring harness clamp brackets.
| 12. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY |
Remove the 3 bolts and No. 2 cylinder head cover.
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| 13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY |
- NOTICE:
- If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.
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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Disconnect the ventilation hose.
Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
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Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
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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 nozzle leakage 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.