GSIC - Global Service Information Center

# FUEL INJECTOR > REMOVAL

## for Preparation Click here

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

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

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

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

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

      SST
        09023-12701

6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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.

1. Disconnect the 4 connectors.

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

7. REMOVE INJECTOR ASSEMBLY

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.

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.