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 OUTLET ELBOW


    1. A003G3V

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

  6. REMOVE FAN AND GENERATOR V BELT


    1. A003FUKE01

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

  7. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A003F0Y

      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.

  8. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. A003GM1

      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.

  9. REMOVE COMPRESSOR AND MAGNETIC CLUTCH


    1. Disconnect the connector.

    2. A003GDE

      Remove the 4 bolts and compressor and magnetic clutch.

  10. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A003AI6E01

      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.

  11. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A003F3C

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

  12. 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.

        A003C66E01

  13. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A003FJRE01

      Remove the union bolt and gasket.

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

  14. DISCONNECT ENGINE WIRE


    1. A003G26

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

    2. A003DPW

      Detach the clamp and disconnect the glow plug connector.

    3. Detach the clamp and disconnect the engine wire from the No. 1 timing belt cover.

    4. Disconnect the 7 connectors.

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

      A003D8Y

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

    7. Remove the terminal cap.

    8. Remove the nut and disconnect the generator wire from terminal B.

    9. Remove the bolt and disconnect the engine wire.

      A003GJRE01

    10. Fold back the floor carpet.

    11. A003CWD

      Remove the bolt.

    12. Detach the clamp.

    13. A003EQY

      Disconnect the ECM connector Click here.

    14. Disconnect the 5 connectors.

    15. Detach the 5 clamps.

  15. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A003BNB

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

    2. A003B9L

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

  16. REMOVE COMMON RAIL ASSEMBLY


    1. A003GQG

      Remove the 2 bolts and common rail.

      Note

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

  17. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    A003DZ4

  18. REMOVE NO. 1 CYLINDER HEAD COVER SILENCER


    1. A003BB7

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

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A003EJZJ01

      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. A003E6V

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

    4. A003FOE

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

  20. REMOVE INJECTOR ASSEMBLY


    1. A003G52E02

      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. A003G9QE01

      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.