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 and fuel inlet pipe, clean them with a brush and compressed air.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
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.
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE DIESEL THROTTLE BODY ASSEMBLY
REMOVE UPPER RADIATOR SUPPORT SEAL
Remove the 13 clips and upper radiator support seal.
REMOVE FRONT BUMPER LOWER COVER
Remove the clip, 5 bolts and front bumper lower cover.
REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
Remove the 4 bolts and No. 1 engine under cover.
DRAIN ENGINE COOLANT
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.
Loosen the radiator drain cock plug.
Collect the coolant in a container and dispose of it according to the regulations in your area.
Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
Loosen the cylinder block drain cock plug.
|*1||Radiator Reservoir||*2||Vent Plug|
|*3||Radiator Drain Cock Plug||*4||Cylinder Block Drain Cock Plug|
REMOVE FRONT WHEEL LH
REMOVE FRONT FENDER APRON SEAL LH
Remove the 5 clips and front fender apron seal LH.
REMOVE INJECTOR DRIVER ASSEMBLY
Disconnect the 4 connectors.
Remove the 2 bolts and injector driver assembly.
DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY
Remove the 3 bolts and disconnect the vane pump oil reservoir.
REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE
Disconnect the 3 vacuum switching valve connectors.
Disconnect the No. 1 vacuum transmitting hose.
Disconnect the 2 No. 2 vacuum transmitting hoses from the No. 2 EGR valve.
Disconnect the No. 1 vacuum transmitting hose and No. 4 vacuum transmitting hose.
Remove the 2 bolts and manifold stay with vacuum switching valve.
REMOVE FUEL INLET PIPE SUB-ASSEMBLY
Remove the bolt and No. 2 injection pipe clamp.
|*a||Common Rail Side|
|*b||Fuel Supply Pump Side|
Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY
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.
Remove the 2 nuts and No. 3 injection pipe clamp.
Remove the 2 bolts and 2 No. 2 injection pipe clamps.
|*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.
DISCONNECT HEATER WATER PIPE SUB-ASSEMBLY
Detach the water by-pass hose clamp.
Remove the bolt and disconnect the heater water pipe.
REMOVE WATER BY-PASS HOSE
Detach the 4 water by-pass hose clamps.
Disconnect the No. 7 water by-pass hose labeled A in the illustration.
Disconnect the No. 4 water by-pass hose labeled B in the illustration.
Disconnect the No. 3 water by-pass hose labeled C in the illustration.
Disconnect the No. 8 water by-pass hose labeled D in the illustration.
Disconnect the No. 6 water by-pass hose labeled E in the illustration.
Disconnect the No. 5 water by-pass hose labeled F in the illustration.
REMOVE NO. 1 VACUUM TRANSMITTING PIPE
Disconnect the vacuum hose from the intake manifold.
Remove the bolt and No. 1 vacuum transmitting pipe.
REMOVE WIRING HARNESS CLAMP BRACKET
Disconnect the glow plug connector.
Detach the 2 wire harness clamps and disconnect the glow plug connector from the wiring harness clamp bracket.
Remove the bolt and wiring harness clamp bracket.
REMOVE NO. 3 ENGINE COVER BRACKET
Remove the 2 nuts and No. 3 engine cover bracket.
REMOVE ENGINE COVER BRACKET INSULATOR
Remove the 2 nuts and 2 engine cover bracket insulators.
REMOVE NO. 4 ENGINE COVER BRACKET
Remove the bolt and No. 4 engine cover bracket.
REMOVE AIR CONNECTOR STAY
Disconnect the 4 injector connectors and detach the 3 wire harness clamps.
|*1||No. 1 Fuel Pipe|
Remove the bolt labeled A and disconnect the No. 1 fuel pipe from the air connector stay.
Remove the 3 bolts and air connector stay.
REMOVE EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY
Disconnect the fuel pressure sensor connector from the common rail.
Remove the 4 nuts, 3 bolts and EGR cooler with No. 2 EGR valve.
Remove the 2 gaskets from the cylinder head and electric EGR control valve.
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY
Disconnect the electric EGR control valve connector.
|*1||Intake Air Connector|
Remove the electric EGR control valve and gasket from the intake air connector.