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.

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.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)

Click here
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.

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.

w/ Intercooler:

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

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.

w/o Intercooler:

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.

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

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

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.

DISCONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)
1. Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.
REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)
1. w/ Intercooler:
  1. Disconnect the 2 connectors.
  2. Disconnect the 6 vacuum hoses.
  3. Remove the bolt and No. 1 gas filter with gas filter bracket.
  4. Remove the 2 bolts and electric vacuum regulating valve.
2. w/o Intercooler:
  1. 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.
REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ Intercooler)
1. Remove the 3 nuts, No. 2 intake air connector and gasket.
REMOVE INTAKE AIR CONNECTOR (w/ Intercooler)
1. Remove the 3 bolts, intake air connector and 2 gaskets.
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)
1. Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.

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.

w/ Intercooler:

Remove the bolt and disconnect the injection pipe clamp.

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.

w/o Intercooler:

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

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.

REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
1. Disconnect the 3 fuel hoses.
2. Text in Illustration
  
  *1 Union Bolt
  
  w/ Intercooler:
  
  Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.
3. Text in Illustration
  
  *1 Union Bolt
  
  w/o Intercooler:
  
  Remove the union bolt, 2 bolts, No. 2 nozzle leakage pipe and gasket.
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. 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. Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
5. Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
REMOVE INJECTOR ASSEMBLY
1. 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. 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.