FUEL INJECTOR(w/o 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.

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. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  11. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  12. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  13. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  14. REMOVE NO. 1 GAS FILTER

    Click here

  15. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  16. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  18. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  19. REMOVE INTAKE AIR CONNECTOR

    Click here

  20. REMOVE NO. 1 AIR HOSE

    Click here

  21. REMOVE NO. 3 AIR TUBE

    Click here

  22. REMOVE NO. 2 AIR HOSE

    Click here

  23. REMOVE NO. 4 AIR TUBE

    Click here

  24. REMOVE NO. 2 AIR CLEANER PIPE 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. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  32. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  33. REMOVE INJECTION PIPE LH

    Click here

  34. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

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

    Click here

  36. REMOVE INJECTION PIPE RH

    Click here

  37. DISCONNECT NO. 2 ENGINE WIRE

    Click here

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


    1. B00185Q

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

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


    1. B001AJN

      Disconnect the 2 vacuum hoses.

    2. B0018BJ

      Remove the 3 bolts and vacuum transmitting pipe.

  40. REMOVE NO. 3 VENTILATION HOSE

    Click here

  41. REMOVE CYLINDER HEAD COVER SILENCER LH


    1. B0018MC

      Remove the 3 bolts and cylinder head cover silencer.

  42. REMOVE NOZZLE HOLDER SEAL LH


    1. B00197A

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

      Tech Tips

      Tape the screwdriver tip before use.

  43. REMOVE OIL SEPARATOR ASSEMBLY


    1. B0019KS

      Remove the 3 bolts, oil separator and gasket.

  44. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B001AD8

      Remove the 17 bolts, cylinder head cover and gasket.

  45. REMOVE NOZZLE HOLDER GASKET LH


    1. B0019OI

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tech Tips

      Tape the screwdriver tip before use.

  46. REMOVE NO. 2 VENTILATION HOSE

    Click here

  47. REMOVE CYLINDER HEAD COVER SILENCER RH


    1. B001988

      Remove the 3 bolts and cylinder head cover silencer.

  48. REMOVE NOZZLE HOLDER SEAL RH


    1. B001AQ1

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

      Tech Tips

      Tape the screwdriver tip before use.

  49. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. B0019Y7

      Remove the 18 bolts, cylinder head cover and gasket.

  50. REMOVE NOZZLE HOLDER GASKET RH


    1. B0019OI

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE FUEL INJECTOR RH


    1. B001A0V

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

      Text in Illustration
      B00199O Union Bolt

      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.

    2. B00185D

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

      Tech Tips

      Arrange the injectors, 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.

  52. REMOVE FUEL INJECTOR LH


    1. B0019W8

      Remove the union bolt, 4 hollow screws, 5 gaskets and No. 2 nozzle leakage pipe.

      Text in Illustration
      B00199O Union Bolt

      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.

    2. B0019AR

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

      Tech Tips

      Arrange the injectors, 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.