1. Disconnect breather tube (1) and blow-by tube (2), and remove cylinder head cover (3).
2. Disconnect injector harness connectors (4) (at 6 places) and move the harnesses.
3. Disconnect fuel high-pressure tube (5).
4. Loosen injector terminal nut (6) and remove
the terminal from the injector.
5. Move the cylinder to be tested to the compression
top dead center.
a See “Adjusting valve clearance”.
6. Remove rocker arm assembly (7).
connector (9).
8. Remove holder (10).
9. Remove injector (11).
a Remove the injector using puller D1 and
the impact of slide hammer.
a Do not unclench the upper part of the
injector.
10. Install gasket D4 to the tip of adapter D3 and
connect it to the injector mount.
11. Fix adapter D3 with the injector holder. 3Holder mounting bolt
1st time: 9.8 ± 2.0 Nm {1.0 ± 0.2 kgm}
2nd time: 40.2 ± 3.9 Nm {4.1 ± 0.4 kgm}
12. Connect gauge assembly D2 to adaptor D3.
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
13. Install rocker arm assembly. 3Rocker arm assembly mounting bolt:
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
14. Adjust valve clearance.
a See “Adjusting valve clearance”.
15. Connect INSITE (troubleshooting kit) to the
engine and set the engine in the no-injection
cranking mode. k If the engine is not set in the no-injection cranking mode, it will start during
testing and will be dangerous. Accordingly, be sure to set the engine in this mode.
16. Rotate the engine with the starting motor and measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
17. After finishing testing, remove the testing tools
and return the removed parts.
a Install the injector and fuel high-pressure tube according to the following procedure.
1) Mate protrusion (a) of the injector with notch (b) of the holder, and set the injector to the cylinder head.
a Set the injector with the above mating position toward the fuel inlet connector insertion side.
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