REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)
REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for Engine Mounting)
Fuel Injector (W/O Dpf) -- Removal |
- NOTICE:
- When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.
| 1. PRECAUTION |
- NOTICE:
- 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. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).
Disconnect the cables from the negative (-) main battery and sub-battery terminals.
| 3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH |
Remove the 3 bolts and screw.
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Loosen the clip and remove the front fender splash shield LH.
| 4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH |
Remove the 3 bolts and 2 screws.
Loosen the clip and remove the front fender splash shield RH.
| 5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY |
Remove the 10 bolts and No. 1 engine under cover.
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| 6. REMOVE UPPER RADIATOR SUPPORT SEAL |
Remove the 7 clips and upper radiator support seal.
| 7. 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.
- HINT:
- Collect the coolant in a container and dispose of it according to the regulations in your area.
Loosen the radiator drain cock plug.
Remove the radiator reservoir cap to drain the coolant in the radiator.
Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.
Tighten the radiator drain cock plug by hand.
Tighten the oil filter bracket drain cock plug.
- Torque:
- 13 N*m{133 kgf*cm, 10 ft.*lbf}
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| 8. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler) |
| 9. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler) |
Loosen the No. 1 air hose clamp.
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Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.
Remove the 3 nuts, bolt and No. 1 cool air inlet.
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Remove the gasket from the air tube RH.
| 10. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler) |
Loosen the No. 2 air hose clamp.
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Remove the 3 nuts, bolt and No. 2 cool air inlet.
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Remove the gasket from the air tube LH.
| 11. DISCONNECT WATER HOSE SUB-ASSEMBLY |
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| *A | w/ Rear Heater |
| *B | w/o Rear Heater |
| 12. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE |
Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.
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Disconnect the ventilation hose from the cylinder head cover RH.
Text in Illustration *A w/ DPF *B w/o DPF
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Remove the 2 bolts and No. 2 engine oil level dipstick guide.
Remove the O-ring from the No. 2 engine oil level dipstick guide.
| 13. REMOVE AIR TUBE SUB-ASSEMBLY RH |
Loosen the hose clamp.
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Remove the air tube from the throttle body.
| 14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH |
Disconnect the throttle position sensor connector.
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Disconnect the throttle motor connector.
Remove the 2 bolts, 2 nuts and throttle body.
Remove the gasket from the intake pipe.
| 15. DRAIN CLUTCH FLUID (for Manual Transmission) |
| 16. REMOVE CLUTCH HOSE (for Manual Transmission) |
Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.
- NOTICE:
- Do not bend or damage the flexible hose tubes.
- Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.
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Remove the 2 clips.
Remove the bolt and clutch hose.
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| 17. REMOVE AIR TUBE SUB-ASSEMBLY LH |
Loosen the hose clamp.
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Remove the air tube from the throttle body.
| 18. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission) |
Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.
- NOTICE:
- Do not bend or damage the flexible hose tube.
- Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.
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Remove the 2 bolts and tube connector to flexible hose tube.
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| 19. REMOVE NO. 1 GAS FILTER |
Disconnect the hose from the intake pipe.
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Remove the No. 1 gas filter.
| 20. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET |
for Manual Transmission:
Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.
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Remove the 2 bolts and No. 3 intercooler support bracket.
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| 21. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH |
Disconnect the throttle position sensor connector.
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Disconnect the throttle motor connector.
Remove the 2 bolts, 2 nuts and throttle body.
Remove the gasket from the intake pipe.
| 22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY |
Loosen the hose clamp.
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Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.
Detach the 4 clamps and remove the air cleaner cap.
| 23. REMOVE NO. 1 AIR CLEANER HOSE |
Loosen the hose clamp and remove the No. 1 air cleaner hose.
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| 24. REMOVE INTAKE AIR CONNECTOR |
w/ Viscous Heater:
Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.Text in Illustration *A w/ Viscous Heater
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w/o Viscous Heater:
Disconnect the connector from the water temperature sensor.
Using a clip remover, detach the 3 wire harness clamps.
Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.
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| 25. REMOVE NO. 3 AIR TUBE |
Disconnect the wire harness from the clamp.
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Remove the nut and ground wire.
Remove the bolt and disconnect the wire harness bracket.
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Loosen the hose clamp and remove the bolt and No. 3 air tube.
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| 26. REMOVE NO. 2 AIR HOSE |
Loosen the hose clamp and remove the No. 2 air hose.
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| 27. REMOVE NO. 4 AIR TUBE |
Remove the bolt and disconnect the suction hose.
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Loosen the hose clamp and remove the bolt and No. 4 air tube.
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| 28. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY |
Disconnect the ventilation hose from the oil separator.
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Loosen the hose clamp.
Remove the bolt and No. 2 air cleaner pipe.
| 29. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater) |
Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.
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| 30. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY |
Loosen the hose clamp.
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Remove the bolt and No. 1 air cleaner pipe.
| 31. DISCONNECT FUEL HOSE |
w/ DPF:
Text in Illustration *a for Fuel Filter with Heater *b for Fuel Filter without Heater
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w/o DPF:
Text in Illustration *a for Fuel Filter with Heater *b for Fuel Filter without Heater
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| 32. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater) |
Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.
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| 33. REMOVE NO. 4 WATER BY-PASS PIPE |
w/ EGR System:
Remove the 2 bolts and nut.
Text in Illustration *A w/ DPF *B w/o DPF w/ DPF:
Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.w/o DPF:
Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.
w/o EGR System:
Remove the 2 bolts and nut.
Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.
| 34. DISCONNECT ENGINE WIRE |
LH Side:
Disconnect the 4 connectors.
Using a clip remover, detach the 3 wire harness clamps.
Disconnect the 2 connectors.
Using a clip remover, detach the 3 wire harness clamps.
Disconnect the 8 connectors.
Text in Illustration *A w/ DPF *B w/o DPF Remove the bolt and engine wire harness bracket labeled B.
Using a clip remover, detach the wire harness clamp labeled D.
Remove the 2 bolts and disconnect the engine wire protector labeled A.
for RHD:
Disconnect the wire harness from the wire harness clamp holder labeled C.
RH Side:
Disconnect the 7 connectors.
Text in Illustration *A w/ DPF *B w/o DPF Using a clip remover, detach the wire harness clamp.
Remove the 3 bolts and disconnect the wire harness protector labeled A.
Remove the bolt and wire harness bracket labeled B.
Remove the screw grommet, nut and glow plug wire harness labeled C.
for RHD:
Disconnect the wire harness from the wire harness clamp holder.Text in Illustration *A w/ DPF *B w/o DPF for RHD:
Remove the bolt and wire harness clamp holder.
Rear Side:
Using a clip remover, detach the wire harness clamp.
Text in Illustration *A w/ DPF *B w/o DPF Remove the 2 bolts and 2 ground wires labeled C.
Remove the 2 bolts and disconnect the engine wire harness protector labeled B.
w/ DPF:
Disconnect the 3 connectors.w/o DPF:
Disconnect the connector.Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.
| 35. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY |
- NOTICE:
- After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel pipe ends, cover the fuel pipe ends with plastic bags.
- After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel supply pump hole, cover the hole with protective tape.
Disconnect the fuel hose from the No. 5 nozzle leakage pipe.
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Remove the bolt and No. 2 injection pipe clamp.
Remove the union bolt and gasket.
Remove the bolt, nut and No. 2 fuel pipe.
| 36. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY |
- NOTICE:
- After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.
w/ EGR System:
Using a union nut wrench, loosen the No. 6 injection pipe ends.
Remove the 2 nuts and 2 No. 2 injection pipe clamps.
Remove the No. 6 injection pipe.
w/o EGR System:
Using a union nut wrench, loosen the No. 6 injection pipe ends.
Remove the nut and No. 2 injection pipe clamp.
Remove the bolt and No. 6 injection pipe.
| 37. REMOVE INJECTION PIPE LH |
w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.Text in Illustration *A w/ DPF *B w/o DPF
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Using a union nut wrench, remove the 4 injection pipes.
Text in Illustration *A w/ DPF *B w/o DPF - NOTICE:
- After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.
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| 38. REMOVE COMMON RAIL ASSEMBLY LH |
Remove the 2 bolts and common rail.
Text in Illustration *A w/ DPF *B w/o DPF - NOTICE:
- Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.
- w/ DPF:
Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.
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| 39. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY |
w/ DPF:
Remove the bolt and No. 2 injection pipe clamp.
Disconnect the fuel hose.
Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.
w/o DPF:
Disconnect the 2 hoses from the fuel pipe.
Remove the bolt and fuel filter to injection pump fuel pipe.
| 40. REMOVE INJECTION PIPE RH |
w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.Text in Illustration *A w/ DPF *B w/o DPF
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Using a union nut wrench, remove the 4 injection pipes.
Text in Illustration *A w/ DPF *B w/o DPF - NOTICE:
- After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.
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| 41. DISCONNECT NO. 2 ENGINE WIRE |
Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.
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| 42. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for Engine Mounting) |
Disconnect the 2 vacuum hoses.
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Remove the bolt and vacuum switching valve.
| 43. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY |
w/ Intercooler:
Disconnect the 2 vacuum hoses.
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Remove the 3 bolts and vacuum transmitting pipe.
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| 44. REMOVE NO. 3 VENTILATION HOSE |
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| *A | w/ DPF |
| *B | w/o DPF |
| 45. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ Intercooler) |
Remove the 3 bolts and cylinder head cover silencer.
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| 46. REMOVE NOZZLE HOLDER SEAL LH |
Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.
- HINT:
- Tape the screwdriver tip before use.
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| 47. REMOVE OIL SEPARATOR ASSEMBLY |
Remove the 3 bolts, oil separator and gasket.
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| 48. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH |
Remove the 17 bolts, cylinder head cover and gasket.
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| 49. REMOVE NOZZLE HOLDER GASKET LH |
Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.
- HINT:
- Tape the screwdriver tip before use.
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| 50. REMOVE NO. 2 VENTILATION HOSE |
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| *A | w/ DPF |
| *B | w/o DPF |
| 51. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ Intercooler) |
Remove the 3 bolts and cylinder head cover silencer.
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| 52. REMOVE NOZZLE HOLDER SEAL RH |
Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.
- HINT:
- Tape the screwdriver tip before use.
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| 53. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH |
Remove the 18 bolts, cylinder head cover and gasket.
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| 54. REMOVE NOZZLE HOLDER GASKET RH |
Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.
- HINT:
- Tape the screwdriver tip before use.
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| 55. REMOVE FUEL INJECTOR RH |
Remove the union bolt, 4 hollow screws, 5 gaskets and nozzle leakage pipe.
Text in Illustration 
Union Bolt - NOTICE:
- 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.
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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.
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Remove the O-ring from each injector.
Remove the 4 injection nozzle seats from the cylinder head.
| 56. REMOVE FUEL INJECTOR LH |
Remove the union bolt, 4 hollow screws, 5 gaskets and No. 2 nozzle leakage pipe.
Text in Illustration Union Bolt - NOTICE:
- 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.
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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.
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Remove the O-ring from each injector.
Remove the 4 injection nozzle seats from the cylinder head.