FUEL INJECTOR INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL INJECTOR ASSEMBLY

   Note:

   • Before installing the injector assembly, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head sub-assembly and injector assembly. If there is foreign matter, remove it before installing the injector assembly.

   • 

     Make sure to replace the copper sealing ring on the injector assembly.

     Table 1. Text in Illustration

     *1	Copper Sealing Ring
     *a	Point Above the Copper Sealing Ring
     *b	Injector Assembly Slot End

   • Before installing the injector assemblies to the injector assembly slots, apply a light coat of highly heat-resistant grease from above the top of the copper sealing ring to the injector assembly slot end.

   • Check the installation position of the high pressure connection.

   • Make sure to read the adjustment values each time new injector assemblies are installed.

   Tip:

   • Perform "Inspection After Repairs" after replacing the fuel injector assembly (Click here).

   • Retighten the clamping claw rest (cylinder head cover mounting).

     Torque

     10 N*m (102 kgf*cm, 7 ft.*lbf)

   1. Install the 4 injector assemblies to the cylinder head cover sub-assembly.

   2. Step 1:

      Using an E10 "TORX" socket wrench, install the 4 clamping claws to the 4 injector assemblies with the 4 centering rings and 4 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

      Note:

      Make sure the screw centering ring is correctly positioned in order to align the clamping claw.

   3. Step 2:

      Using an E10 "TORX" socket wrench, tighten the 4 bolts.

      26 N*m

      265 kgf*cm

      19 ft.*lbf

   4. Connect the 4 injector assembly connectors.

2. CONNECT NOZZLE LEAKAGE PIPE ASSEMBLY

   1. Install 4 new sealing rings to the nozzle leakage pipe assembly.

   2. 

      Connect the nozzle leakage pipe assembly to the 4 injector assemblies and push down the 4 clips to install the nozzle leakage pipe assembly.

      Table 2. Text in Illustration

      *1	Sealing Ring
      *2	Leakage Line
      *3	Clip
      *a	Push Down

   3. 

      Connect the connector and attach the 2 clamps to connect the wire harness.

3. INSTALL CAMSHAFT POSITION SENSOR

   Click here

4. INSTALL INJECTION PIPE SUB-ASSEMBLY

   Note:

   • If the pressure lines are leaking after installation, they must be replaced.

   • Do not overtighten the pressure lines.

   1. Temporarily install the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies at the common rail assembly end by hand.

   2. 

      Using a SST, tighten the 4 union nuts at the common rail assembly end of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies as shown in the illustration.

      SST

      PZ4TB-04959-10

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Note:

      Reset SST in a timely manner to prevent bending of pressure lines.

   3. Using SST, tighten the 4 union nuts at the 4 injector assembly ends of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST

      PZ4TB-04959-10

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Note:

      Reset SST in a timely manner to prevent bending of pressure lines.

   4. Check all components of the common rail system for tightness.

5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

   Note:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

6. PERFORM REGISTRATION

   1. Perform registration of injector compensation codes (Click here).

7. INSTALL ENGINE COVER

8. INSTALL NO. 1 ENGINE COVER

   Click here

9. INSPECT FOR FUEL LEAK

   Click hereClick here