FUEL INJECTOR (w/o DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Remove the electric EGR control valve assembly Click here.

  3. DISCONNECT INLET HEATER WATER HOSE (w/o EGR System)


    1. A00JUQI

      Remove the bolt and disconnect the inlet heater water hose.

  4. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)


    1. A00JWMM

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

  5. REMOVE NO. 1 INTAKE PIPE (w/o EGR System)


    1. A00JZLQ

      Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

    2. Detach the 2 clamps.

    3. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    4. A00JWSR

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A00JV3H

      Loosen the hose clamp of the intercooler air hose.

    6. A00K23L

      Remove the 2 bolts and No. 1 intake pipe.

  6. REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A00OA28

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  7. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR System)

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A00XH0D

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

    2. A00XH1Z

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

    3. A00XJETE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  8. REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A00O30T

      Remove the 3 bolts and air connector stay.

  9. DISCONNECT ENGINE WIRE (w/o EGR System)


    1. A00O8HT

      for LHD:

      Remove the 2 bolts and disconnect the clamp and engine wire.

    2. A00OA2U

      for RHD:

      Remove the bolt and disconnect the engine wire.

  10. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)


    1. A00O7OP

      Disconnect the throttle position sensor connector.

    2. A00O5VW

      Remove the 3 bolts, intake air connector with diesel throttle and gasket.

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. A00O5P2

        w/o EGR System:

        Disconnect the connector.

      2. A00O70W

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. A00O5WE

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. A00O3VL

      Disconnect the No. 1 vacuum transmitting hose.

    3. A00OB6W

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

    4. A00OAHN

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. A00O4FYE03
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    6. A00O5B8

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  12. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XF0Y

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A00XHHME06
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  13. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A00JZXEE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  14. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00O7AGE01
      Text in Illustration
      *1 Union Bolt

      Disconnect the 3 fuel hoses.

    2. Remove the union bolt, 4 bolts, No. 2 nozzle leakage pipe and gasket.

  15. REMOVE VENTILATION PIPE


    1. A00O8AJ

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

  16. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00XHHE

      Disconnect the 4 injector connectors.

    2. Detach the 2 wire harness clamps and disconnect the wire harness from the No. 2 cylinder head cover.

    3. A00XENP

      Remove the 4 bolts and No. 2 cylinder head cover.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A00XD84E01

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

    2. A00XH2E

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    3. A00XCKH

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  18. REMOVE INJECTOR ASSEMBLY


    1. A00XEY5E04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and 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.

    2. A00XGHLE01

      Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, No. 1 nozzle 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.