FUEL INJECTOR (w/o DPF) REMOVAL


  1. CHECK INJECTOR COMPENSATION CODE


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

    2. If they 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 "resister injection compensation code" 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 have been caused by errors in injection compensation code registration.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Remove the radiator cap.

    2. Loosen the radiator drain cock plug and a cylinder block drain cock plug. Then drain the coolant.

      A01BC1SE01

  4. REMOVE FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  5. REMOVE FRONT DOOR SCUFF PLATE RH

  6. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet, and remove the 5 bolts and engine service hole sub cover sub-assembly.

  7. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

    1. Remove the 2 bolts, and separate the vane pump oil reservoir assembly.

  8. DISCONNECT OIL RETURN HOSE

    A01BCQX

    1. Loosen the 2 clips.

    2. Disconnect the oil return hose.

  9. REMOVE EGR COOLER ASSEMBLY

    A01BH3G

    1. Loosen the clip and disconnect the No. 4 water by-pass hose.

    2. Loosen the clip and disconnect the No. 2 water by-pass hose.

    3. A01BDC3

      Remove the 3 bolts and 2 nuts and remove the EGR cooler assembly.

  10. REMOVE NO. 4 AIR HOSE

    A01BGX6

    1. Install the No. 4 air hose with the 2 clamps.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  11. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    A01BCMO

    1. Disconnect the 2 throttle body connectors.

    2. A01BBJH

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

    3. Remove the gasket from the intake air connector.

  12. REMOVE NO. 2 ENGINE SERVICE HOLE COVER

    A01BD0S

    1. Remove the 3 bolts and No. 2 engine service hole cover.

  13. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01BBVC

      Disconnect the intake air temperature sensor connector.

    2. Remove the vacuum regulating valve.


      1. A01BDUS

        Remove the 2 vacuum hoses and the vacuum regulating valve connector.

      2. A01BH0B

        Remove the 2 bolts and the vacuum regulating valve.

    3. A01BBMB

      Remove the electric EGR control valve with the sensor.


      1. Remove the bolt, and separate the manifold stay.

      2. Disconnect the vacuum hose from the intake air connector.

      3. A01BHKK

        Disconnect the EGR valve position sensor connector.

      4. Disconnect the vacuum hose from the electric EGR control valve.

      5. Remove the bolt, 2 nuts and intake air connector assembly.

      6. A01BACYE02

        Remove the 2 gaskets and electric EGR control valve from the intake air connector.

  14. REMOVE OIL LEVEL GAUGE GUIDE

    A01BF6Z

    1. Remove the oil level gauge.

    2. Remove the bolt and remove the oil level gauge guide.

  15. REMOVE INJECTION PIPE

    A01BALH

    1. Disconnect the fuel injector connector and harness clamps.

    2. Remove the 3 bolts.

    3. A01BEJA

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

    4. A01BFN0

      Using SST, remove the 4 injection pipes.

      SST
      09023-12701

  16. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A01BC23

    1. Remove the 2 clamp bolts.

    2. A01BDF3

      Using SST, loosen the 2 union nuts and remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  17. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    A01BBPS

    1. Disconnect the 4 fuel hoses from the No. 2 nozzle leakage pipe assembly.

    2. A01BGX5

      Remove the 2 union bolts, 3 bolts and remove the No. 2 nozzle leakage pipe assembly.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A01BAID

    1. Using a small screwdriver, remove the 4 holder seals by prying the portion between the holder seal and the cutout part of the cylinder head.

    2. Disconnect the ventilation hose.

    3. A01BF0S

      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.

  19. REMOVE INJECTOR ASSEMBLY

    A01BGQ1

    1. Remove the nozzle leakage pipe assembly.


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

        Note

        Cover the plastic bag to prevent any foreign matter from entering the injector.

    2. A01BA83

      Remove the nozzle holder clamps.


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

        Note

        Be sure to keep the removed bolts, washers, and nozzle holder clamps separate for each cylinder.

    3. Remove the injector assemblies.

    4. Put tags with cylinder numbers (#1 to #4) on the removed injectors in order to match them into the correct cylinders.