Injector Removal and Installation
Special Tools Required
Image Description/Tool Number
9576255.png Pick Up Tool 070AC-5A00100
9507972.png Injector Seal Installer Kit 070AG-5A00100

Flammable - Keep Fire Away

NOTE:
enu_12713377_2.0 Where icon is shown, click for further information.
Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line.
Fuel may cause flammable gas leaks and may result in fire. Keep sparks, flame and cigarettes away.
When replacing the injector, you must replace all injectors on the fuel rail as a set and the fuel joint pipe.
Failure to do so will cause poor engine performance and fuel leaks.


1


1559_3.0_enu_14724350_8.0

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Detailed information, notes and precautions
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Replace


NOTE:
Do not disconnect the water bypass hoses.
Do not bend the water bypass hoses excessively.

4. Intake Manifold Bracket - Remove

6. High Pressure Fuel Pump Cover - Remove

8. Bracket - Remove


9. Fuel Rail and Injector - Remove
1.
Carefully remove the fuel rail with the injectors straight from the cylinder head.
NOTE:
If the injector remains on the cylinder head, carefully remove the injector straight from the cylinder head.
Note the cylinder number of the injector, and install it to the same cylinder when reinstalling.
If you replace the injector, the fuel rail, or the cylinder head, use a new injector clip.

10. Injector - Remove
1.
Remove the injectors (A) from the fuel rail.
2.
Remove the injector clip (B), the O-ring (C), and the back-up ring (D) from the injector.
NOTE: If you replace the injector, the fuel rail, or the cylinder head, use a new injector clip, O-ring, and back-up ring.
3.
Using the pick up tool (A), carefully remove the seal (B) from the injector.


Flammable - Keep Fire Away

NOTE:
enu_12713377_2.0 Where icon is shown, click for further information.
Fuel may cause flammable gas leaks and may result in fire. Keep sparks, flame and cigarettes away.
Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line.
When replacing the injector, you must replace all injectors on the fuel rail as a set.


1


1559_3.0_enu_14724355_8.0

enu_12713377_2.0
Detailed information, notes and precautions
enu_12714505_1.0
Torque: N·m (kgf·m, lbf·ft)
enu_12714524_1.0
Replace
*1
Coat the clean engine oil

1. Injector Seal - Install
NOTE:
Do not wipe off the tip area (A) of the injector as it may be damaged.
If the tip of the injector is dirty or clogged, it must be replaced. The injectors cannot be cleaned.
1.
Use compressed air to ensure that there are no dust or debris around the ring (B).
2.
With a paper towel, carefully wipe off any carbon from the area (C) shown.
3.
Quickly push a new seal (A) down to the groove (B) of the injector using the seal guide tool (C) and the seal installer (D).
4.
Joint the sizing tools (A), then slide them as a set onto the seal (B) until tools touch to the injector stepped surface (C) as shown, and hold the tools to reform the seal for 30 seconds or more.
5.
Remove the sizing tools, and check that the seal is installed correctly.
NOTE: When cleaning the sizing tool, be careful not to scratch the sizing tool bore.
6.
Install a new back-up ring (A) and a new O-ring (B) on the injector (C).
NOTE:
Set the direction of the back-up ring as shown
Check that the back-up ring sets correctly after installation.
7.
Coat the O-ring with clean engine oil, then install the injector onto the fuel rail (D) with a new clip (E).
NOTE: When installing the injector, be sure to protect the injector from dust or debris.

2. Fuel Rail and Fuel Injector - Install
1.
Carefully install the fuel rails with the injectors into the cylinder head straight and equal.
NOTE: When installing the injector, protect the tip of the injector from dust or debris.
2.
Install the nuts, and tighten them slowly in an alternating pattern until the fuel rail sits on the cylinder head.
3.
Tighten the nuts and the bolts to the specified torque.


NOTE: Failure to install a new fuel joint pipe will cause fuel leaks.

4. Bracket - Install


6. High Pressure Fuel Pump Cover - Install
1.
Install the high pressure fuel pump cover (A).
NOTE: The cover will be reinstalled after the fuel leak check.