Tools & parts you’ll need
- Basic hand tools: metric sockets, open-end wrenches, flat/Pozidriv screwdrivers, pick set.
- Injector removal tool or small injector puller (if injector is pressed/seized).
- Clean catch pan, rags, disposable tray for small parts.
- Multimeter (DC volts/ohms).
- 12 V jumper lead with insulated clips (fused jumper or bench power supply recommended).
- Fuel pressure gauge / hand primer or inline hand pump (optional but recommended for bench spray test).
- Small bench vise or clamp (soft jaws) for teardown if required.
- Replacement parts: cold-start injector assembly (OEM part), O‑rings/seals, sealing washers, small inlet screen/strainer if fitted.
- Clean diesel, safety solvent, and soft-bristle brush.
- PPE: safety glasses, nitrile gloves, fire extinguisher nearby.

Safety first (read before doing anything)
- Work in a well‑ventilated area away from open flames and hot surfaces. Diesel and vapors are flammable.
- Disconnect battery negative before removing electrical connectors or fuel components. Remove jewelry.
- Relieve any fuel system pressure before opening lines. Catch fuel in a safe container and dispose properly.
- Use a fused jumper lead when energizing solenoids to avoid accidental short/high current.
- If you must crank the engine during tests, keep hands clear of moving parts and ensure vehicle is secured (transmission in neutral/park, wheels chocked).

Step‑by‑step: locate and remove cold‑start injector
1. Identify location: on W04-series Hino engines the cold‑start injector (cold start valve) is typically mounted on or near the intake manifold/throttle body area and fed from the low‑pressure fuel supply. Confirm with your engine layout/service manual.
2. Prepare the engine: allow to cool, remove engine covers/air cleaner for access. Place drip pan under injector area.
3. Disconnect battery negative.
4. Relieve fuel pressure: loosen a fuel line connection at a downstream fitting and allow pressure to bleed into the catch pan. Capture fuel and plug lines to limit contamination.
5. Clean area thoroughly with rags and solvent so no dirt falls into the fuel system when the injector is removed.
6. Disconnect the electrical connector from the cold‑start injector (press release tab, pull straight). Inspect connector for corrosion/damage.
7. Disconnect fuel hose/pipe to the injector. Use line wrenches if flare fittings are used. Have rags ready.
8. Remove any retaining hardware: small bolts, clips or a threaded body. Use the appropriate socket/wrench or a small injector puller if the injector is stuck. Be gentle to avoid bending or breaking the housing.
9. Extract the injector straight out. Inspect O‑rings and sealing surfaces. If O‑rings are stuck to the manifold, remove them carefully.

Bench inspection and basic testing
10. Visual inspection: check spray tip for carbon build‑up, pins for damage, and body for cracks. Replace if physically damaged.
11. Electrical test: measure coil resistance with a multimeter. Compare to the factory spec in the service manual. Expect a low‑ohm solenoid reading (consult manual; if open circuit or wildly out of expected range, replace the injector).
12. Functional (spray) test — safe method:
- Reconnect fuel supply to the injector or place the injector into a small cup of clean diesel and clamp it in a vise with rubber or soft jaws.
- Apply 12 V briefly to the solenoid using a fused jumper or bench power supply while supplying fuel pressure (hand primer or the vehicle’s pump during cranking). You should see a sharp, atomized spray or hear a distinct click and see fuel flow when energized.
- Do not energize continuously for long periods. Use short pulses (1–2 seconds) to avoid burning the coil or creating heat.
- If you cannot supply fuel pressure, do not attempt to test by spraying inflammable solvents—use the service manual’s recommended bench test rig or replace the unit.
13. If the injector fails electrical or spray tests, replace the injector and install new O‑rings/seals.

Reinstall procedure
14. Fit new O‑rings/seals to the injector. Lightly lubricate O‑rings with clean diesel or specified lubricant to avoid tearing during installation.
15. Insert injector straight into manifold; ensure correct orientation and seat fully. Replace any sealing washers.
16. Tighten retaining bolts/nut to manufacturer torque (lookup in service manual). Do not overtighten — risk of cracking casting or deforming seals.
17. Reconnect fuel line and tighten fittings securely. Replace any crush washers if specified.
18. Reconnect electrical connector. Reconnect battery negative.

Commissioning and checks
19. Prime the fuel system: operate the hand primer or cycle the ignition per manual to restore pressure and remove air. Check for leaks at the injector and fittings.
20. Start the engine and observe: on cold cranking the cold‑start injector should operate only during the initial crank/start cycle (governed by the cold start relay/ECU or manual switch). Watch for proper start and no fuel dripping when the system is off.
21. After warm‑up, verify the cold‑start injector does not remain energized (if it does, check wiring, relay, timer or engine sensors).

Common pitfalls and how to avoid them
- Not relieving fuel pressure: causes fuel spray and mess; always bleed first.
- Dirty work area: contaminant entry will clog small fuel passages — clean thoroughly before removal.
- Reusing old O‑rings: these often harden and leak. Replace every time.
- Over‑energizing the solenoid: can burn the coil — use short test pulses and fused power.
- Over‑torquing or misaligning injector: can damage threads, warp sealing surfaces or break the injector body. Use correct torque.
- Bench testing without fuel supply: you may hear a click but not confirm spray; the click alone is not proof of good spray/atomization.
- Reinstalling with damaged connector pins or frayed wiring: results in intermittent operation. Repair wiring or replace connector.
- Using the wrong replacement part: cold‑start injectors are engine‑specific. Use OEM or exact equivalent.

When replacement is required
- Replace if electrical resistance is out of spec, coil is open/shorted, spray pattern is weak or dribbling, tip is damaged, or injector sticks open.
- Always fit new O‑rings/seals and any specified inlet screens/filters. If harness connectors are corroded, replace or rebuild the connector.

Final note
- Consult the Hino W04-series service manual for explicit location diagrams, coil resistance and torque specs before final assembly. Follow the manual’s electrical wiring/relay diagnosis if the injector does not operate after replacement.
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