FUEL INJECTOR (w/ DPF) REMOVAL

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.


  1. PRECAUTION

    Note

    After turning the ignition 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


    1. A015DL0

      Remove the 3 bolts and screw.

    2. Loosen the clip and remove the front fender splash shield LH.

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Remove the 3 bolts and 2 screws.

    2. Loosen the clip and remove the front fender splash shield RH.

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


    1. A0157XJ

      Remove the 10 bolts and No. 1 engine under cover.

  6. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 7 clips and upper radiator support seal.

  7. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Collect the coolant in a container and dispose of it according to the regulations in your area.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator reservoir cap to drain the coolant in the radiator.

    3. Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

      A015DKUE01

    4. Tighten the radiator drain cock plug by hand.

    5. A0158UW

      Tighten the oil filter bracket drain cock plug.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  8. REMOVE INTERCOOLER ASSEMBLY

    Click here

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0159QI

      Loosen the hose clamp.

    2. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

    3. Detach the 4 clamps and remove the air cleaner cap.

  10. REMOVE NO. 1 AIR CLEANER HOSE


    1. A0159QI

      Loosen the hose clamp.

    2. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

    3. Detach the 4 clamps and remove the air cleaner cap.

  11. REMOVE INTAKE AIR CONNECTOR


    1. A015852E04
      Text in Illustration
      *A w/ Viscous Heater

      w/ Viscous Heater:

      Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

    2. w/o Viscous Heater:

      Disconnect the connector from the water temperature sensor.

    3. Using a clip remover, detach the 3 wire harness clamps.

    4. A015DJJ

      Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

  12. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0156LC

      Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

    2. A015C0GE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the ventilation hose from the cylinder head cover RH.

    3. Remove the 2 bolts and No. 2 engine oil level dipstick guide.

    4. Remove the O-ring from the No. 2 engine oil level dipstick guide.

  13. REMOVE AIR TUBE SUB-ASSEMBLY RH


    1. A0155DE

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH


    1. A0159VX

      Disconnect the throttle position sensor connector.

    2. Disconnect the throttle motor connector.

    3. Remove the 2 bolts, 2 nuts and throttle body.

    4. Remove the gasket from the intake pipe.

  15. REMOVE AIR TUBE SUB-ASSEMBLY LH


    1. A015B7A

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  16. REMOVE NO. 1 GAS FILTER


    1. A01591S

      Disconnect the hose from the intake pipe.

    2. Remove the No. 1 gas filter.

  17. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    1. A0156KS

      for Manual Transmission:


      1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.

    2. A0157EZ

      Remove the 2 bolts and No. 3 intercooler support bracket.

  18. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH


    1. A015A91

      Disconnect the throttle position sensor connector.

    2. Disconnect the throttle motor connector.

    3. Remove the 2 bolts, 2 nuts and throttle body.

    4. Remove the gasket from the intake pipe.

  19. REMOVE NO. 1 AIR HOSE


    1. A0158SB

      Loosen the hose clamp and remove the No. 1 air hose.

  20. REMOVE NO. 3 AIR TUBE


    1. A0159U8

      Disconnect the wire harness from the clamp.

    2. Remove the nut and ground wire.

    3. A0155HD

      Remove the bolt and disconnect the wire harness bracket.

    4. A01572L

      Loosen the hose clamp and remove the bolt and No. 3 air tube.

  21. REMOVE NO. 2 AIR HOSE


    1. A0155DS

      Loosen the hose clamp and remove the No. 2 air hose.

  22. REMOVE NO. 4 AIR TUBE


    1. A015A8F

      Remove the bolt and disconnect the suction hose.

    2. A015577

      Loosen the hose clamp and remove the bolt and No. 4 air tube.

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


    1. A015AEL

      Disconnect the ventilation hose from the oil separator.

    2. Loosen the hose clamp.

    3. Remove the bolt and No. 2 air cleaner pipe.

  24. DISCONNECT WATER HOSE SUB-ASSEMBLY

    A015CADE02
    Text in Illustration
    *A w/ Rear Heater
    *B w/o Rear Heater

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


    1. A0158HY

      Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

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


    1. A015D8F

      Loosen the hose clamp.

    2. Remove the bolt and No. 1 air cleaner pipe.

  27. DISCONNECT FUEL HOSE


    1. A0159B1E01
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/ DPF:

    2. A0159IIE01
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/o DPF:

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


    1. A015DM6

      Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

  29. REMOVE NO. 4 WATER BY-PASS PIPE


    1. w/ EGR System:


      1. Remove the 2 bolts and nut.

        A0157IQE01
        Text in Illustration
        *A w/ DPF *B w/o DPF

      2. w/ DPF:

        Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

      3. w/o DPF:

        Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.

    2. w/o EGR System:


      1. A0157AC

        Remove the 2 bolts and nut.

      2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

  30. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. A015D5V

        Disconnect the 4 connectors.

      2. Using a clip remover, detach the 3 wire harness clamps.

      3. A015AFR

        Disconnect the 2 connectors.

      4. Using a clip remover, detach the 3 wire harness clamps.

      5. Disconnect the 8 connectors.

        A015AYBE01
        Text in Illustration
        *A w/ DPF *B w/o DPF

      6. Remove the bolt and engine wire harness bracket labeled B.

      7. Using a clip remover, detach the wire harness clamp labeled D.

      8. Remove the 2 bolts and disconnect the engine wire protector labeled A.

      9. for RHD:

        Disconnect the wire harness from the wire harness clamp holder labeled C.

    2. RH Side:


      1. Disconnect the 7 connectors.

        A015AIHE01
        Text in Illustration
        *A w/ DPF *B w/o DPF

      2. Using a clip remover, detach the wire harness clamp.

      3. Remove the 3 bolts and disconnect the wire harness protector labeled A.

      4. Remove the bolt and wire harness bracket labeled B.

      5. Remove the screw grommet, nut and glow plug wire harness labeled C.

      6. A015CM3E01
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

      7. for RHD:

        Remove the bolt and wire harness clamp holder.

    3. Rear Side:


      1. A0157RZE01
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        Using a clip remover, detach the wire harness clamp.

      2. Remove the 2 bolts and 2 ground wires labeled C.

      3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

      4. w/ DPF:

        Disconnect the 3 connectors.

      5. w/o DPF:

        Disconnect the connector.

      6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.

  31. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.


    1. w/ EGR System:


      1. A0157JU

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.

      3. Remove the No. 6 injection pipe.

    2. w/o EGR System:


      1. A0159AO

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the nut and No. 2 injection pipe clamp.

      3. Remove the bolt and No. 6 injection pipe.

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


    1. A01576L

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

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


    1. A015AL5

      Disconnect the 2 vacuum hoses.

    2. A0159QH

      Remove the 3 bolts and vacuum transmitting pipe.

  34. REMOVE CYLINDER HEAD COVER SILENCER LH


    1. A015AO1

      Remove the 4 bolts and cylinder head cover silencer.

  35. REMOVE NO. 2 FUEL INJECTOR PROTECTOR


    1. A0156K1

      Detach the hose clamp.

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

  36. REMOVE NO. 4 NOZZLE LEAKAGE PIPE


    1. A01571T

      Disconnect the fuel hose.

    2. Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

  37. REMOVE INJECTION PIPE LH


    1. A015B4EE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. A015E5OE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  38. REMOVE NO. 5 NOZZLE LEAKAGE PIPE


    1. w/ DPF:


      1. Disconnect the fuel hose.

      2. A015E4L

        Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

    2. A0156LG

      w/o DPF:

      Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

  39. REMOVE COMMON RAIL ASSEMBLY LH


    1. A015BWVE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail.

      Note


      • Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.

      • w/ DPF:

        Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.

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


    1. w/ DPF:


      1. A015D39

        Remove the bolt and No. 2 injection pipe clamp.

      2. Disconnect the fuel hose.

      3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.

    2. w/o DPF:


      1. A01588A

        Disconnect the 2 hoses from the fuel pipe.

      2. Remove the bolt and fuel filter to injection pump fuel pipe.

  41. REMOVE CYLINDER HEAD COVER INSULATOR LH

    A015B24

  42. REMOVE CYLINDER HEAD COVER SILENCER RH


    1. A015AD8

      Remove the 4 bolts and cylinder head cover silencer.

  43. REMOVE NO. 1 FUEL INJECTOR PROTECTOR


    1. A0156CK

      Remove the bolt and No. 1 fuel injector protector.

  44. REMOVE INJECTION PIPE RH


    1. A0155GHE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. A015B9WE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  45. REMOVE CYLINDER HEAD COVER INSULATOR RH

    A015AZ4

  46. DISCONNECT NO. 2 ENGINE WIRE


    1. A0156MM

      Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

  47. DISCONNECT CONNECTING WIRE


    1. A0158N3

      Detach the 2 clamps and remove the connecting wire.

  48. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A0155NQ

      Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

  49. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A0156JO

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 No. 2 Check Valve
      A0158FK 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. A015611

      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.

    2. Remove the O-ring from each injector.

    3. Remove the 4 injection nozzle seats from the cylinder head.

  51. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A015BOU

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 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. A0157BA

      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.

    2. Remove the O-ring from each injector.

    3. Remove the 4 injection nozzle seats from the cylinder head.