Removal
Note. In the case of the vehicle equipped with immobilizer or button engine start system, perform "Key Teaching" procedure together. Refer to TEACHING PROCEDURES .
Scheme 109
Scheme 110
- Turn ignition switch OFF and disconnect the negative (-) battery cable.
- Disconnect the ECM Connector (A).
- Remove the air cleaner assembly. Refer to «INTAKE AND EXHAUST SYSTEM»(ref-429537) .
- Remove the mounting bolts (A) and nut (B), and then remove the ECM assembly (C).
- Remove the installation nuts (A) and screw (B), and then remove the ECM (C) from the bracket.
Scheme 111
Installation
Note. In the case of the vehicle equipped with immobilizer or button engine start system, perform "Key Teaching" procedure together. Refer to TEACHING PROCEDURES .
- Installation is reverse of removal.
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
ECM bracket installation bolt/nut
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Remove the resonator and the air intake hose. Refer to «INTAKE AND EXHAUST SYSTEM»(ref-429537) .
- Disconnect the ETC module connector.
- Disconnect the coolant hoses (B).
- Remove the installation bolts (A), and then remove the ETC module from the engine.
Scheme 112
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
- Installation is reverse of removal.
Electronic throttle body Installation bolt
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | Insert the sensor in the installation hole and be careful not to damage. |
- Installation is reverse of removal. Manifold absolute pressure sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | Apply the engine coolant to the O-ring. |
| CAUTION | Insert the sensor in the installation hole and be careful not to damage. |
- Installation is reverse of removal.
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | Apply the engine oil to the O-ring. |
| CAUTION | Insert the sensor in the installation hole and be careful not to damage. |
- Installation is reverse of removal.
Crankshaft position sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Crankshaft position sensor protector installation bolt (M6): 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Crankshaft position sensor protector installation bolt (M8): 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
| CAUTION | DON'T remove the camshaft position sensor while the engine is running or right after engine is turned off. The part and engine oil is hot and can cause burns. |
Scheme 113
Scheme 114
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Disconnect the camshaft position sensor connector (A).
- Remove the installation bolt (B), and then remove the sensor. Bank 1/Exhaust Turn the ignition switch OFF and disconnect the battery negative (-) cable. Remove the heater protect cover. Refer to «EXHAUST MANIFOLD»(ref-429537-S10061567342011101500000) . Disconnect the camshaft position sensor connector (A). Remove the hanger and the protector. Remove the installation bolt, and then remove the sensor.
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | Apply the engine oil to the O-ring. |
| CAUTION | Insert the sensor in the installation hole and be careful not to damage. |
| CAUTION | Be careful not to damage the sensor housing and the connector. Be careful not to damage the O-ring. |
- Installation is reverse of removal.
Camshaft position sensor installation bolt
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Remove the intake manifold. Refer to «INTAKE AND EXHAUST SYSTEM»(ref-429537) .
- Disconnect the knock sensor connector (A).
- Remove the installation bolt (B), and then remove the sensor from the cylinder block.
Scheme 115
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
- Installation is reverse of removal.
Knock sensor installation bolt
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Disconnect the connector (A), and then remove the sensor (B).
Note. Note that the SST (Part No.: 09392-2H100) is useful when removing the heated oxygen sensor.
Scheme 116
Scheme 117
Scheme 117: Bank 1/Sensor 1
Scheme 118
Scheme 119
Scheme 119: Bank 1/Sensor 2
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | DON'T use a cleaner, spray, or grease to sensing element and connector of the sensor because oil component in them may malfunction the sensor performance. Sensor and its wiring may be damaged in case of contacting with the exhaust system (Exhaust Manifold, Catalytic Converter, and so on). |
- Installation is reverse of removal.
Heated oxygen sensor installation (Bank 1/Sensor 1)
39.2 ~ 49.1 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
Heated oxygen sensor installation (Bank 1/Sensor 2)
35 ~ 45 N.m (3.6 ~ 4.6 kgf.m, 25.8 ~ 33.2 lb-ft)
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Release the residual pressure in fuel line. Refer to «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(ref-429555-S11766373352011101500000) . CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.
- Remove the intake manifold. Refer to «INTAKE AND EXHAUST SYSTEM»(ref-429537) .
- Disconnect the rail pressure sensor connector (A), and then remove the sensor (B) from the delivery pipe.
Scheme 120
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
- Installation is reverse of removal.
Rail Pressure Sensor Installation: 18.0 ~ 22.0 N.m (1.8 ~ 2.2 kgf.m, 13.3 ~ 16.2 lb-ft)
- Turn the ignition switch OFF.
- Disconnect the OTS connector (A).
- Remove the OTS.
Scheme 121
- Installation is reverse of removal.
Refer to ACCELERATOR PEDAL .
Refer to ACCELERATOR PEDAL .
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | Insert the sensor in the installation hole and be careful not to damage. |
- Installation is reverse of removal.
| WARNING | In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops. |
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Release the residual pressure in fuel line. Refer to «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(ref-429555-S11766373352011101500000) . CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.
- Remove the delivery pipe & injector assembly. Refer to «DELIVERY PIPE»(ref-429555-S14413366952011101500000) .
- Remove the fixing clip (A), and then separate the injector from the delivery pipe.
Scheme 122
| CAUTION | Do not reuse the injector retaining clip, O-ring, backup ring, washer seal or combustion seal ring. Once an injector is removed, the five components must be replaced with new ones. |
Scheme 123
- Combustion seal
- Rubber washer
- Support disc
- O-ring
Note. Item 1, 3 and 4 are supplied in a single kit.
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | Apply engine oil to the injector O-ring. Do not reuse the used injector O-ring. |
| CAUTION | Do not reuse the delivery pipe mounting bolts. Once the delivery pipe is removed, the bolts must be replaced with new ones. |
| CAUTION | When inserting the injector, be careful not to damage the injector tip. |
| CAUTION | When replacing the washer seal, the steel plate (A) part should be faced the cylinder installation part and the rubber plate (B) part should be faced the injector body part. |
Scheme 124
| CAUTION | Do not reuse the combustion seal. Be careful not to apply engine oil on the combustion seal ring. |
| CAUTION | Avoid dropping the fuel pipe (including injectors) or bumping it into any hard objects since damage to the internal components may occur. If necessary, visually inspect and confirm proper operation with performance tests prior to reuse. Before installing the injector into the cylinder head, clean the injector hole and avoid contaminants from entering inside the injector hole. When installing the injector, avoid bumping the injector tip into any of the surrounding components since the tip may become damaged from the impact. When fastening the three fuel delivery pipe mounting bolts, fully hand-tighten first, and then tighten in the proper sequence ((1) --> (2) --> (3)) in several cycles up to the specified torque. The delivery pipe should move less than 1/8 inch (approx. 3 mm), whenever each bolt is tightened. |
Scheme 125
- Installation is reverse of removal.
Replacement
The injector combustion seal should be replaced new one to prevent leakage after removing the injector.
Scheme 126
Scheme 127
Scheme 128
Scheme 129
Scheme 130
Scheme 131
Scheme 132
Scheme 133
Scheme 134
Scheme 135
Scheme 136
Scheme 137
Scheme 138
- Remove the combustion seal (A) with a wire cutter. CAUTION: Grip the sealing ring carefully, pull it to form a small loop and then cut it. Be careful not to damage the surface of the valve sleeve with the wire cutter.
- Before the assembly of the sealing ring the groove must be cleaned using a clean cloth. Any coking of the injector sealing surface must be carefully removed with a brass-wire brush. CAUTION: The surfaces of the new sealing ring must be clean and free of grease.
- Place the combustion seal on the cone and pull downward on the seal as indicated in the photo. NOTE: Your fingers will work better for installing the Combustion Seal over the cone.
- Pull the seal downward until it is near the bottom of the cone as shown in the photo.
- Place the cone (with seal) on the end of the injector. Place the sizing tool (SST No.: 09353-2B000) over the cone. Make sure the tool flange is toward the seal as shown. Press down on the tool to work the seal over the injector and into the groove.
- Because the seal will stretch as it goes over the end of the injector, it will be a bit oversized after installation. By letting the injector and seal set for a few minutes, the seal may reduce in size. Inspect the seal for damage before continuing.
- Place the resizing tool (flange up) over the seal. Twist the tool slightly while pushing down over the seal. This should reduce the size of the seal. CAUTION: Be careful not to apply engine oil on the combustion seal ring.
- Place injector into the head as shown.
- Twist slightly while pressing the injector into position in the head. This should complete the resizing of the seal. Remove the injector and inspect the seal before completing the injector installation process.
- If the injector comes with a protective steel washer held in place by a spring clip, both will have to be removed before installation.
- Install the Washer Seal onto injector with the rubber side (stepped) toward the injector.
- The stepped rubber side of the seal goes towards the injector.
- The flat washer side of the seal goes towards the head.
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
- Use care to keep foreign material out of the valve.
| CAUTION | Install the purge control solenoid valve after lifting the support pin (A) of the bracket. |
Scheme 139
- Installation is reverse of removal.
Purge control solenoid valve bracket installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Remove the OTS (A).
- Disconnect the CVVT oil control valve connector (B).
- Remove the installation bolt (C), and then remove the valve from the engine.
Scheme 140
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Disconnect the CVVT oil control valve connector (A).
- Remove the installation bolt (B), and then remove the valve from the engine.
Scheme 141
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
| CAUTION | Apply engine oil to the valve O-ring. |
- Installation is reverse of removal.
CVVT oil control valve installation bolt
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Refer to HIGH PRESSURE FUEL PUMP .
- Installation is the reverse order of removal.
- Turn the ignition switch OFF and disconnect the battery negative (-) cable.
- Remove the RCV control solenoid valve (A) after disconnect the connector, bolt and hose.
Scheme 142
- Installation is the reverse order of removal.
| CAUTION | Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
- Installation is reverse of removal.
