FUEL INJECTOR (w/ EGR Cooler) REMOVAL

Note


  • 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, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE FUEL TANK CAP ASSEMBLY

  3. REMOVE INTERCOOLER ASSEMBLY


    1. Remove the intercooler assembly Click here.

  4. CHECK FOR INJECTOR COMPENSATION CODE

    Tech Tips

    If the injector compensation code is not correctly registered, it may cause malfunctions.


    1. Read the injector compensation code Click here.

    2. Check that compensation code of installed injector is same as code registered in ECM. If the code is not as specified, register the injector compensation code on the injector Click here.

  5. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01DZU7E01

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A01DYA8E01

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    3. A01DWONE05

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  6. REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE


    1. Remove the EGR cooler with electric EGR control valve and No. 2 EGR valve Click here.

  7. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01E10I

      Remove the bolt and disconnect the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01DVY2E05

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A01E177

      Remove the 3 bolts and disconnect the 4 connectors.

    2. A01DXC5E01

      Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.

    3. Disconnect the ventilation hose.

    4. A01DZGHE01

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    5. A01DV31

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  9. REMOVE INJECTOR ASSEMBLY


    1. A01E29AE01

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


      • 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 fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01DW1AE01

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.