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EXHAUST FUEL ADDITION INJECTOR (for DPF) REMOVAL

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Note:

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.

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  1. Click here

    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. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

  3. Click here

    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. Click here

    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. Click here

    REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A0157XJ

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

  6. Click here

    REMOVE UPPER RADIATOR SUPPORT SEAL


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

  7. Click here

    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.

    Tip:

    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. A015DKUE01

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

    4. Tighten the radiator drain cock plug by hand.

    5. A0158UW

      Tighten the oil filter bracket drain cock plug.

      13 N*m 133 kgf*cm 10 ft.*lbf
  8. Click here

    REMOVE INTERCOOLER ASSEMBLY

    (Click here)

  9. Click here

    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. Click here

    REMOVE NO. 1 AIR CLEANER HOSE


    1. A015DGT

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

  11. Click here

    REMOVE INTAKE AIR CONNECTOR


    1. A015852E04

      w/ Viscous Heater:

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

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

    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. Click here

    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

      Disconnect the ventilation hose from the cylinder head cover RH.

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

    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. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY RH


    1. A0155DE

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  14. Click here

    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. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY LH


    1. A015B7A

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  16. Click here

    REMOVE NO. 1 GAS FILTER


    1. A01591S

      Disconnect the hose from the intake pipe.

    2. Remove the No. 1 gas filter.

  17. Click here

    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. Click here

    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. Click here

    REMOVE NO. 1 AIR HOSE


    1. A0158SB

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

  20. Click here

    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. Click here

    REMOVE NO. 2 AIR HOSE


    1. A0155DS

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

  22. Click here

    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. Click here

    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. Click here

    DISCONNECT WATER HOSE SUB-ASSEMBLY

    Table 3. Text in Illustration
    *A w/ Rear Heater
    *B w/o Rear Heater
  25. Click here

    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. Click here

    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. Click here

    DISCONNECT FUEL HOSE


    1. A0159B1E01

      w/ DPF:

      Table 4. Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater
    2. A0159IIE01

      w/o DPF:

      Table 5. Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater
  28. Click here

    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. Click here

    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. A015AYBE01

        Disconnect the 8 connectors.

        Table 6. 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. A015AIHE01

        Disconnect the 7 connectors.

        Table 7. 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

        for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

        Table 8. Text in Illustration
        *A w/ DPF
        *B w/o DPF

      7. for RHD:

        Remove the bolt and wire harness clamp holder.

    3. Rear Side:


      1. A0157RZE01

        Using a clip remover, detach the wire harness clamp.

        Table 9. Text in Illustration
        *A w/ DPF
        *B w/o DPF

      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.

  30. Click here

    REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01576L

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

  31. Click here

    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.

  32. Click here

    REMOVE CYLINDER HEAD COVER SILENCER LH


    1. A015AO1

      Remove the 4 bolts and cylinder head cover silencer.

  33. Click here

    REMOVE NO. 2 FUEL INJECTOR PROTECTOR


    1. A0156K1

      Detach the hose clamp.

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

  34. Click here

    REMOVE CYLINDER HEAD COVER SILENCER RH


    1. A015AD8

      Remove the 4 bolts and cylinder head cover silencer.

  35. Click here

    REMOVE NO. 1 FUEL INJECTOR PROTECTOR


    1. A0156CK

      Remove the bolt and No. 1 fuel injector protector.

  36. Click here

    REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY


    1. A0156BHE01

      Disconnect the 2 exhaust fuel addition injector connectors.

      Table 10. Text in Illustration
      *A for Bank 1
      *B for Bank 2
    2. A015D22E01

      Remove the 2 bolts, 2 washers and 2 nozzle holder clamps.

      Table 11. Text in Illustration
      *A for Bank 1
      *B for Bank 2
      *1 Washer
      *2 Nozzle Holder Clamp

    3. Remove the 2 exhaust fuel addition injectors and 2 gaskets.

  37. Click here

    DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A015A47E01

      Turn the 2 retainers shown in the illustration.

      Table 12. Text in Illustration
      *A for Bank 1
      *B for Bank 2
      Note:

      • Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

      • Do not forcefully bend, kink or twist the nylon tube.

      • Keep the fuel tube connector and fuel pipe free from foreign matter.

      • Put the fuel tube connector and fuel pipe in plastic bags to prevent damage and contamination.

    2. A015817E01

      Disconnect the 2 fuel tube connectors from the exhaust fuel addition injector.

      Table 13. Text in Illustration
      *1 Fuel Tube Connector
      *2 Exhaust Fuel Addition Injector
      *3 Retainer
      *4 O-Ring
  38. Click here

    REMOVE FUEL INJECTOR SEAL


    1. A015B4VE01

      Remove the 2 fuel injector seals.

      Table 14. Text in Illustration
      *1 Fuel Injector Seal