FUEL INJECTOR(w/ DPF) REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.

  • When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  7. DRAIN ENGINE COOLANT

    Click here

  8. REMOVE INTERCOOLER ASSEMBLY

    Click here

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  11. REMOVE INTAKE AIR CONNECTOR

    Click here

  12. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  13. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  15. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  16. REMOVE NO. 1 GAS FILTER

    Click here

  17. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  18. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  19. REMOVE NO. 1 AIR HOSE

    Click here

  20. REMOVE NO. 3 AIR TUBE

    Click here

  21. REMOVE NO. 2 AIR HOSE

    Click here

  22. REMOVE NO. 4 AIR TUBE

    Click here

  23. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  24. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  25. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  26. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  27. DISCONNECT FUEL HOSE

    Click here

  28. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  29. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  30. DISCONNECT ENGINE WIRE

    Click here

  31. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  32. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for Engine Mounting)


    1. w/ Spare Tire:


      1. B001A9N

        Disconnect the 2 vacuum hoses.

      2. Remove the bolt and vacuum switching valve.

  33. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. B0019N8

      Disconnect the 2 vacuum hoses.

    2. B001B51

      Remove the 3 bolts and vacuum transmitting pipe.

  34. REMOVE CYLINDER HEAD COVER SILENCER LH


    1. B001AFN

      Remove the 4 bolts and cylinder head cover silencer.

  35. REMOVE NO. 2 FUEL INJECTOR PROTECTOR


    1. B0018DH

      Detach the hose clamp.

    2. Remove the bolt and No. 2 fuel injector protector.

  36. REMOVE NO. 4 NOZZLE LEAKAGE PIPE

    Click here

  37. REMOVE INJECTION PIPE SUB-ASSEMBLY LH

    Click here

  38. REMOVE NO. 5 NOZZLE LEAKAGE PIPE

    Click here

  39. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

  40. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  41. REMOVE CYLINDER HEAD COVER INSULATOR LH

    B001ADV

  42. REMOVE CYLINDER HEAD COVER SILENCER RH


    1. B001ADK

      Remove the 4 bolts and cylinder head cover silencer.

  43. REMOVE NO. 1 FUEL INJECTOR PROTECTOR


    1. B0018KQ

      Remove the bolt and No. 1 fuel injector protector.

  44. REMOVE INJECTION PIPE SUB-ASSEMBLY RH

    Click here

  45. REMOVE CYLINDER HEAD COVER INSULATOR RH

    B001AEX

  46. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  47. DISCONNECT CONNECTING WIRE

    Click here

  48. REMOVE NO. 3 NOZZLE LEAKAGE PIPE

    Click here

  49. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. B001AXE

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      B0018FC Injector Hollow Screw
      B00199O No. 2 Check Valve
      B001A0Q Union Bolt

    2. Remove the No. 2 check valve from the fuel tube and No. 1 nozzle leakage pipe.

    3. Remove the union bolt and No. 1 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 nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  50. REMOVE FUEL INJECTOR RH


    1. B0018D0

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps, 4 nozzle holder seals and 4 fuel injectors.

      Tech Tips

      Arrange the fuel injectors, holder clamps, washers and bolts in the correct order.

    2. Remove the O-ring from each fuel injector.

    3. Remove the 4 fuel injector seals from the fuel injector.

    4. Remove the 4 injection nozzle seats from the cylinder head sub-assembly.

  51. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. B001B2M

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      B0018FC Injector Hollow Screw
      B00199O Bolt

    2. Remove the 2 bolts and No. 2 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 nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  52. REMOVE FUEL INJECTOR LH


    1. B0019AQ

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps, 4 nozzle holder seals and 4 fuel injectors.

      Tech Tips

      Arrange the fuel injectors, holder clamps, washers and bolts in the correct order.

    2. Remove the O-ring from each fuel injector.

    3. Remove the 4 fuel injector seals from the fuel injector.

    4. Remove the 4 injection nozzle seats from the cylinder head sub-assembly.