FUEL INJECTOR REMOVAL


  1. CHECK ID CODE


    1. Check that each injection compensation code registered in the injector assembly installed on each cylinder matches the ones registered in the ECM Click here.

    2. If any of the codes do not match, follow the procedures below to correct the registration details and recheck the symptom.


      1. Correct the registration details by following the procedures in "INPUT INJECTOR COMPENSATION CODE(S) INTO ECM" Click here.

      2. After correcting the registration details, check if the same symptom occurs as when the vehicle was brought in.

        Tech Tips

        If it does not occur, the symptom may be caused by errors in injection compensation code registration.

  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. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CIF0E01

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap, then drain the coolant.

    3. Close the radiator drain cock plug.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf, for the engine drain plug }

  4. REMOVE NO. 2 INTAKE PIPE


    1. A01CHOY

      Remove the 3 bolts, loosen the 2 bands, and remove the No. 2 intake pipe.

  5. REMOVE NO. 1 AIR HOSE


    1. A01CIUN

      Remove the 2 bolts and hose clamp, and then remove the No. 1 air hose.

  6. REMOVE NO. 4 AIR HOSE


    1. A01CJ8A

      Loosen the 2 clamps and remove the No. 4 air hose.

  7. REMOVE EGR COOLER SUB-ASSEMBLY


    1. Separate the water by-pass hose.

    2. Remove the 6 bolts and EGR cooler.

  8. SEPARATE WIRE HARNESS AND CONNECTORS


    1. A01CJDO

      Disconnect the 3 connectors, 3 connector clamps and bolt.

  9. REMOVE EGR VALVE BRACKET


    1. A01CISY

      Remove the 4 bolts and bracket.

  10. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJ16

      Disconnect the hoses from the EGR valve assembly.

    2. A01CJ9R

      Remove the 3 bolts, 2 union bolts, and 4 gaskets and separate the water by-pass pipe sub-assembly.

  11. REMOVE DIESEL THROTTLE BODY


    1. A01CHFJ

      Disconnect the 2 diesel throttle body connectors.

    2. A01CH93

      Remove the 2 bolts, 2 nuts and diesel throttle body.

  12. REMOVE VENTURI ASSEMBLY


    1. Remove the 4 bolts, 2 nuts and venturi from the intake manifold.

  13. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01CJFY

      Remove the oil filler cap sub-assembly.

  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CJGU

      Remove the 2 bolts and cylinder head cover sub-assembly.

  15. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CGZM

      Remove the wire harness.

    2. Remove the cylinder head cover cushion rubber.

    3. Remove the 2 bolts and No. 2 cylinder head cover sub-assembly.

  16. REMOVE INJECTION PIPE CLAMP


    1. A01CGTY

      Remove the 2 nuts.

    2. Remove the oil level gauge guide and O-ring, and then remove the 2 injection pipe clamps.

  17. REMOVE INJECTOR ASSEMBLY


    1. A01CHN3

      Using a union nut wrench (17 mm), loosen the 8 union nuts and remove the injection pipe sub-assembly.

    2. A01CGVZ

      Remove the 5 hollow screws and 5 gaskets, and then remove the nozzle leakage pipe.

      Tech Tips

      After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating the injectors.

    3. A01CIVM

      Using a small screwdriver, remove the 4 holder seals.

    4. A01CGOO

      Remove the 4 bolts and the 4 nozzle holder clamps.

      Note

      Arrange the holder clamps and bolts in the correct order.

    5. Remove the 4 injectors.

      Note

      Arrange the injectors in the correct order.

    6. Remove the No. 2 cylinder head cover gasket from each injector.

    7. A01CI6EE01

      Remove the O-ring from each injector.

  18. REMOVE INJECTION NOZZLE SEAT GASKET


    1. Remove the 4 injection nozzle seat gaskets from the cylinder head.