Removal and Installation of Injectors

Injector damage can cause engine knock and bearing damage. To locate a faulty injector, loosen the union nuts of the high-pressure supply lines one by one. If the knocking stops when a particular nut is loosened, the faulty injector has been found. Injectors can be checked with a special tester.

Signs of a faulty injector are as follows:
a) No fuel ignition in the cylinder.
b) Knocking in one or more cylinders.
c) Engine overheating.
d) Excessively thick black exhaust smoke.
e) Loss of engine power. Increased fuel consumption.
f) Thick blue exhaust smoke when the engine is cold.

REMOVAL
1. Clean the injection lines with an aerosol cleaner to prevent contamination from entering the system when it is opened.
2. Remove the intake manifold. Refer to the section Removal and Installation of Intake Manifold.
3. Disconnect the high-pressure fuel lines from the injectors and the injection pump using wrench (1), such as HAZET 4550. Refer to the accompanying illustration.

* Do not bend the lines. Fit protective caps on the injector and injection pump openings to prevent dirt from entering.

4. If the line brackets are removed, first mark their position with a felt-tip pen. Refer to the accompanying illustration.

5. Carefully disconnect the drain pipes from the injectors.
6. Remove the injectors using a 27 mm socket, such as HAZET 4555-1. The injectors are protected at the bottom by caps.

* Make sure the injectors do not fall. In addition, disconnect the cable of the built-in injection timing sensor from the 4th cylinder injector. Install all injectors in their original positions.

7. Remove the heat shield gaskets.

INSTALLATION
1. Always install new heat shield gaskets for the injectors. The recess in the gaskets must face upward. The arrow in the illustration points toward the cylinder head.

2. Screw in the injectors and tighten them to the torque specified in the Specifications.
3. Tighten the lines to the required torque.
4. Install the drain hoses.
5. Connect the injection start sensor cable to the No. 4 cylinder injector.
6. Install the brackets according to the markings, if they were removed.
7. Install the brake booster vacuum hose at the cylinder head bracket.
8. Install the intake manifold. Refer to Intake Manifold Removal and Installation.
9. Start the engine and check the fuel system for leaks.