FUEL INJECTOR INSTALLATION

PROCEDURE


  1. INSTALL INJECTION NOZZLE SEAT

    A01VG1QE01
    Text in Illustration
    *1 Injector
    *2 Sealing Surface
    *3 Nozzle
    *4 Injection Nozzle Seat
    *5 Cylinder Head
    *6 Cloth

    Note


    • When installing, clean the sealing surface of the injector, injection pipe and common rail.

    • When replacing the injectors, the injection pipes must also be replaced.

    • Replace the injection pipe with a new one when the injection pipe has been removed and reinstalled more than 5 times.

    • Replace the injector with one with the same part number and install it onto the cylinder.


    1. Using a cloth and solvent, wipe away any carbon from the sealing surface of the injector and injector installation hole, as shown in the illustration.

      Note


      • Do not damage the sealing surface.

      • Do not touch the injector nozzle.

    2. Install the 4 new nozzle seats onto the cylinder head.

  2. INSTALL INJECTOR ASSEMBLY


    1. Install the 4 injectors onto the cylinder head.

      Tech Tips

      Fit the injectors into the seats.

  3. INSTALL NOZZLE HOLDER CLAMP SEAT


    1. A01VL1WE04
      Text in Illustration
      *1 Nozzle holder clamp seat
      *2 Concave
      *a Upper Side

      Install the 4 nozzle holder clamp seats onto the cylinder head.

      Note

      Install the nozzle holder clamp seats with the concave end facing up.

  4. INSTALL NO. 1 NOZZLE HOLDER CLAMP


    1. A01VHBGE06
      Text in Illustration
      *1 Washer
      *2 Nozzle holder clamp
      *3 Nozzle holder clamp seat
      *a Upper Side

      Install the 4 nozzle holder clamps onto the injectors.

    2. Set the washer on the nozzle holder clamp, as shown in the illustration.

      Note

      Install the washer in the correct direction.

    3. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  5. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01VJU7

      Install the nozzle leakage pipe into each injector.


      1. Make sure the lock bush is at the top position.

        A01VLXSE01
        Text in Illustration
        *1 Lock Bush *2 Return Plug
        *3 Rest Arm *4 Injector
        *a Push - -

      2. Insert the rest arm into the injector and push both sides of the return plug until the rest arm engages with the injector, as shown in the illustration.

        Tech Tips

        Push the nozzle leakage pipe until it makes a click sound.

      3. Push the lock bush until it fits with the return plug, as shown in the illustration.

    2. Connect the 4 injector connectors.

  6. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR


    1. Install the No. 2 intake manifold insulator.

  7. INSTALL NO. 1 GLOW PLUG CONNECTOR

    Click here

  8. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY


    1. Temporarily install 4 new injection pipes onto the injectors and common rail.

      Note

      Install the pipe and union nut vertically, not at a tilt.

      A01VH6PE02
      Text in Illustration
      *a OK
      *b NG

    2. Using a union nut wrench (17 mm), tighten the injection pipe union nut on the common rail, and then tighten the union nut on the injector.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  9. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for No. 1 injection pipe.

  10. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for No. 1 injection pipe.

  11. INSTALL NO. 1 EGR COOLER BRACKET

    Click here

  12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE


    1. Connect the No. 1 air cleaner hose.

    2. Install the air cleaner cap sub-assembly with hose onto the air cleaner case, engage the 2 hooks, and then engage the 2 lock clamps.

    3. Engage the 4 wire harness clamps.

    4. Connect the mass air flow meter connector.

  13. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY

    Click here

  14. INITIALIZATION AND REGISTRATION

    Click here

  15. BLEED AIR FROM FUEL SYSTEM

    Click here

  16. INSPECT FOR FUEL LEAK

    Click here