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 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 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

    CAUTION:

    Do not remove the radiator reservoir 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. Loosen the radiator drain cock plug.

      A003IDXE01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    2. Remove the radiator reservoir cap sub-assembly.

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

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock 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. A003DBM

      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.

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


    1. A003GD3

      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.

  8. REMOVE FRONT DOOR SCUFF PLATE RH

  9. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A003E43E01

      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. A003ICN

      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. A003BPA

      Disconnect the fuel pressure sensor connector.

    2. A003CG8

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

    3. Remove the 2 gaskets.

  13. REMOVE AIR HOSE NO.4


    1. A003DQ1

      Loosen the 2 clamps.

    2. Remove the air hose No.4.

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A003BFR

      Disconnect the 2 throttle body connectors.

    2. A003F09

      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. A003E4Y

      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. A003EYQ

      Remove the bolt, and separate the manifold stay.

    2. Disconnect the vacuum hose from intake air connector.

    3. A003G45E01

      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. A003BEQ

        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. A003FGA

        Remove the bolt, and separate the manifold stay.

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

      3. A003H5T

        Disconnect the intake air temperature sensor connector.

      4. Disconnect the EGR valve position sensor connector.

      5. A003DG5E01

        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. A003C95

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

      2. A003E87

        Using SST, remove the 4 injection pipes.

        SST
        09023-12701

  20. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. A003CDI

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

    2. A003CK1

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

    3. A003DRM

      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. A003HFR

      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. A003D4D

      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. A003FOE

      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. A003G52

        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. A003G9Q

        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.