FUEL INJECTOR (w/ DPF) 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. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. 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 not as specified, register the injector compensation code of the injector Click here.

  4. REMOVE EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY

    Click here

  5. REMOVE COMPRESSOR ELBOW STAY


    1. A01BF8X

      Remove the 2 bolts and compressor elbow stay.

  6. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01BFP8

      Loosen the 2 hose clamps and remove the bolt and compressor outlet elbow.

  7. REMOVE FAN AND GENERATOR V BELT


    1. A01BERGE01

      Remove the drive belt by rotating the tensioner pulley clockwise to loosen its tension with the pulley set bolt of the tensioner.

  8. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A01BGYM

      Remove the bolt and disconnect the cooler refrigerant discharge hose from the compressor and magnetic clutch.

    2. Remove the O-ring from the cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  9. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. A01BDO5

      Remove the bolt and disconnect the cooler refrigerant suction hose.

    2. Remove the O-ring from the cooler refrigerant suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  10. REMOVE COMPRESSOR AND MAGNETIC CLUTCH


    1. Disconnect the connector.

    2. A01BFJ0

      Remove the 4 bolts and compressor and magnetic clutch.

  11. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01BF00E01

      Disconnect the 3 fuel hoses.

    2. Remove the bolt and No. 2 injection pipe clamp from the No. 3 nozzle leakage pipe and No. 3 fuel pipe.

    3. Remove the fuel check valve and gasket.

    4. Remove the bolt and No. 3 nozzle leakage pipe.

  12. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01BCHI

      Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

  13. REMOVE NO. 3 FUEL PIPE

    Tech Tips

    It is not necessary to completely remove the No. 3 fuel pipe from the vehicle.


    1. for Engine LH Side:


      1. Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      2. Remove the fuel check valve and gasket.

      3. Remove the bolt.

    2. for Engine Rear Side:


      1. Remove the union bolt and gasket.

      2. Remove the 2 bolts.

        A01BEYJE01

  14. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01BAXEE01

      Remove the union bolt and gasket.

    2. Remove the 3 bolts and No. 2 nozzle leakage pipe.

  15. DISCONNECT ENGINE WIRE


    1. A01BH3F

      Detach the 3 clamps and disconnect the water by-pass hose and oil return hose.

    2. A01BF0O

      Detach the clamp and disconnect the glow plug connector.

    3. Disconnect the 7 connectors.

    4. Remove the 7 bolts and disconnect the engine wire.

      A01BDFJ

    5. Disconnect the 4 connectors and detach the 3 clamps.

    6. Remove the terminal cap.

    7. Remove the nut and disconnect the wire harness from terminal B.

    8. Remove the bolt and disconnect the engine wire.

      A01BGIGE01

    9. Fold back the floor carpet.

    10. Disconnect the 6 ECM connectors.

    11. A01BEK4

      Remove the bolt.

    12. A01BCV8

      Disconnect the 3 connectors.

  16. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01BAC9

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

    2. A01BEYL

      Using a 17 mm union nut wrench, loosen the union nuts and remove the 4 injection pipes.

  17. REMOVE COMMON RAIL ASSEMBLY


    1. A01BFXR

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.

  18. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    A01BHU8

  19. REMOVE NO. 1 CYLINDER HEAD COVER SILENCER


    1. A01BH9R

      Remove the No. 1 cylinder head cover silencer from the cylinder head cover.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BDCBJ01

      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.

    2. Disconnect the ventilation hose.

    3. A01BGDA

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

    4. A01BGWS

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

  21. REMOVE INJECTOR ASSEMBLY


    1. A01BGQ1E02

      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. A01BA83E01

      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.