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. 2 AIR CLEANER PIPE SUB-ASSEMBLY


A098889E06

  1. Disconnect the manifold absolute pressure sensor connector.

  1. Disconnect the vacuum hose from the gas filter.

  1. Loosen the 2 clamps of the No. 1 and No. 2 air hoses.

  1. Remove the bolt and cleaner pipe together with the 2 air hoses.



5. REMOVE INJECTION PIPE


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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  



6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


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  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.



7. REMOVE INJECTOR ASSEMBLY


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  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.