FUEL INJECTOR REMOVAL


  1. CHECK INJECTION COMPENSATION CODE


    1. Check that the injection compensation code registered in the injector assembly installed on each cylinder match the ones registered in the engine ECU 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 be caused by errors in injection compensation code registration.

  2. REMOVE BATTERY SERVICE HOLE COVER (w/ Sub-Battery)

  3. DISCONNECT BATTERY NEGATIVE CABLE

  4. REMOVE ENGINE UNDER COVER NO.1 (w/ Engine Under Cover)

  5. DRAIN ENGINE COOLANT

    A01BD7XE01

    CAUTION:

    To avoid the danger of being burned, do not remove the reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. Loosen the radiator drain plug.

    2. Remove the reservoir cap.

    3. Loosen the cylinder block drain plug (on the engine oil cooler cover), and drain the coolant.

    4. Tighten the radiator drain plug.

    5. Tighten the cylinder block drain plug (on the engine oil cooler cover).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
  6. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  7. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  8. REMOVE FRONT DOOR SCUFF PLATE RH

  9. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBC4E01

      Remove the 2 bolts and vane pump oil reservoir assembly.

      Note

      Suspend the vane pump oil reservoir assembly with wire to prevent power steering fluid from spilling out.

  10. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


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

  11. DISCONNECT OIL RETURN HOSE (w/ Inter cooler)


    1. A01BFPG

      Loosen the clip.

    2. Disconnect the oil return hose from the intake manifold.

  12. REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BGWP

      Disconnect the fuel pressure sensor connector.

    2. A01BD88

      Remove the 2 bolts, 2 nuts, and the EGR pipe sub-assembly.

    3. Remove the 2 gaskets.

  13. REMOVE AIR HOSE NO.4


    1. A01BGX6

      Loosen the 2 clamps.

    2. Remove the air hose No.4.

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01BCMO

      Disconnect the 2 throttle body connectors.

    2. A01BBJH

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

    3. Remove the gasket from intake air connector.

  15. REMOVE ENGINE SERVICE HOLE COVER NO.2


    1. A01BG4E

      Roll up the carpet.

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

  16. REMOVE INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BDK1

      Remove the bolt, and separate the manifold stay.

    2. Disconnect the vacuum hose from intake air connector.

    3. A01BEP8E01

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

    4. Remove the 2 gaskets and intake air connector No.2 from the intake air connector.

  17. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Remove the vacuum regulating valve.


      1. A01BHSL

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

      2. Remove the 2 bolts and the vacuum regulating valve.

    2. Remove the EGR valve assembly with the sensor.


      1. A01BCF1

        Remove the bolt, and separate the manifold stay.

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

      3. A01BAPE

        Disconnect the intake air temperature sensor connector.

      4. Disconnect the EGR valve position sensor connector.

      5. A01BACYE01

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

      6. Remove the 2 gaskets and EGR valve assembly from the intake air connector.

  18. REMOVE OIL LEVEL GAGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  19. REMOVE INJECTION PIPE

    SST
    09023-12701

    1. Remove the injection pipe.


      1. A01BC89

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

      2. A01BFG2

        Using SST, remove the 4 injection pipes.

        SST
        09023-12701
  20. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. A01BE3U

      Disconnect 3 fuel hoses from nozzle leakage pipe assembly No.2.

    2. A01BEHR

      Remove the union bolt from nozzle leakage pipe No.2.

    3. A01BCQO

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

    4. Remove the gasket from nozzle leakage pipe No.2.

  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BAID

      Using a small screwdriver, remove the holder seal 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.

      Note

      After removing the fuel pipe, put a plastic bag and rubber band to prevent dirt and foreign objects over the injectors inlet.

    4. A01BGWS

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

  22. REMOVE INJECTOR ASSEMBLY


    1. Remove the nozzle leakage pipe assembly.


      1. A01BGQ1

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

        Note

        Cover the plastic bag prevent to the injector.

    2. Remove the nozzle holder clamp.


      1. A01BA83

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

        Note

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

    3. Remove the injector assemblies.