FUEL INJECTOR (w/o 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 and fuel inlet pipe, clean them with a brush and compressed air.


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)

    Click here

  4. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o Intercooler)

    A01E0K7

    1. Disconnect the manifold absolute pressure sensor connector.

    2. Disconnect the vacuum hose from the gas filter.

    3. Loosen the 2 clamps.

    4. Remove the bolt and disconnect the pipe together with the 2 air hoses.

  5. CHECK 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 the compensation code of the installed injector is the same as the code registered in the ECM. If the code is the same, register the injector compensation code on the injector Click here.

  6. 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. w/ Intercooler:


      1. A01DWWA

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

      2. A01E1SS

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

      3. A01DXC6E01
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

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

    2. w/o Intercooler:


      1. A01DXPXE02
        Text in Illustration
        *1 No. 2 Injection Pipe Clamp
        *2 No. 3 Injection Pipe Clamp
        *a Injector Side
        *b Common Rail Side

        Remove the bolt and No. 2 injection pipe clamp.

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

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

  7. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ Intercooler)


    1. A01DVDTE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler
      *1 No. 2 Intake Air Connector Bracket
      *2 Intake Air Connector

      Remove the 3 bolts and No. 2 intake air connector bracket.

  8. DISCONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)


    1. A01DZCR

      Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.

  9. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)


    1. w/ Intercooler:


      1. A01DZHP

        Disconnect the 2 connectors.

      2. A01E31V

        Disconnect the 6 vacuum hoses.

      3. Remove the bolt and No. 1 gas filter with gas filter bracket.

      4. A01DY7U

        Remove the 2 bolts and electric vacuum regulating valve.

    2. w/o Intercooler:


      1. A01DWIO

        Disconnect the connector.

      2. Disconnect the 2 vacuum hoses.

      3. Remove the 2 bolts and electric vacuum regulating valve together with the bracket.

        Note

        Do not remove the electric vacuum regulating valve from the bracket.

  10. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DZS6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  11. REMOVE INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DW3T

      Remove the 3 bolts, intake air connector and 2 gaskets.

  12. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01DX9H

      Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.

  13. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note

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


    1. w/ Intercooler:


      1. A01E10I

        Remove the bolt and disconnect the injection pipe clamp.

      2. A01DVY2E07
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

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

    2. w/o Intercooler:


      1. A01E0ZRE01

        Remove the 2 bolts and disconnect the 2 injection pipe clamps.

      2. A01E2XGE02
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

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

  14. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DVNTE01
      Text in Illustration
      *1 Union Bolt

      w/ Intercooler:

      Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

    3. A01DYKDE01
      Text in Illustration
      *1 Union Bolt

      w/o Intercooler:

      Remove the union bolt, 2 bolts, No. 2 nozzle leakage pipe and gasket.

  15. 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. Remove the 3 bolts and disconnect the 4 injector connectors.

    2. A01DXC5E01

      Using a small screwdriver, remove the nozzle holder seal by prying 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.

  16. REMOVE INJECTOR ASSEMBLY


    1. A01E0K3E01
      Text in Illustration
      *1 Union Bolt

      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. A01DWA9

      Remove the 4 bolts, 4 washers, 4 No. 1 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.