FUEL INJECTOR > REMOVAL

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



1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.



2. LOOSEN FUEL TANK CAP ASSEMBLY


3. DRAIN FUEL


4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    A110362

  1. Remove the 3 bolts, 2 nuts and cover.



5. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR


    A110365

  1. Disconnect the diesel turbo IAT sensor connector.

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



    A110366

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



    A110367

  1. Remove the 4 bolts and CAC.



    A112149

  1. Using a 22 mm deep socket wrench, remove the IAT sensor.

    HINT:
    Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.



    A112150

  1. Remove the 4 bolts, intake air connector and gasket.



6. REMOVE INJECTION PIPE


A098967E02

NOTICE:
  1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
  2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

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

  1. Remove the bolt and No. 2 injection pipe clamp.



  1. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

    SST
    09023-12701  



      A098893E01

    1. Remove the 2 bolts and disconnect the 2 injection pipe clamps.



      2. A098968E01

    2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.

      SST
      09023-12701  



7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


A060180E01

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

  1. Disconnect the ventilation hose.



    G034844E01

  1. Disconnect the 4 connectors.



    G034877E01

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



8. REMOVE INJECTOR ASSEMBLY


A061112E01

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

    NOTICE:
    1. When removing the nozzle leakage pipe, place a cushion under the pipe.
    2. Be careful not to deform or scratch the union seal surface.
    3. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.



    G034876E01

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

    HINT:
    Arrange the injectors, holder clamps, washers and bolts in the correct order.

  1. Remove the O-ring and back-up ring from the injector.

  1. Remove the 4 injection nozzle sheets from the cylinder head.