FUEL INJECTOR INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL INJECTOR ASSEMBLY

    Note

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


    1. Install 4 new nozzle seats to the cylinder head.

    2. A004T04E01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to each injector.

    3. Apply a light coat of engine oil to the O-ring on each injector.

    4. Install the 4 injectors to the cylinder head.

      Note

      Fit the injectors to the nozzle seats.

    5. A004PBDE02
      Text in Illustration
      *1 Washer

      Install the nozzle holder clamps and washers as shown in the illustration.

      Note

      Pay attention to the mounting orientation (beveled edge) of the washer.

    6. Temporarily install the nozzle holder clamp bolts.

      Note

      When temporarily installing the nozzle holder clamp bolt to the nozzle holder clamp, make sure that the bolt and clamp are not at an angle.

      Tech Tips

      Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

    7. Temporarily install the 4 injection pipes.

    8. Temporarily install the No. 1 leakage pipe and 4 new gaskets with the 4 union bolts and bolt.

    9. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  2. INSTALL NO. 1 NOZZLE LEAKAGE PIPE


    1. Tighten the 4 union bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Tighten the bolt.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  3. INSTALL INJECTION PIPE SUB-ASSEMBLY


    1. Using a 14 mm union nut wrench, tighten the 4 nuts at the common rail end of the injection pipes.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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.

    2. Using a 14 mm union nut wrench, tighten the 4 nuts at the injector end of the injection pipes.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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.

    3. Install the 4 injection pipe clamps with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  4. INSTALL NO. 2 NOZZLE LEAKAGE PIPE


    1. Temporarily install the No. 2 nozzle leakage pipe and a new gasket with the check valve and bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the bolt.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    4. Using pliers, grip the claws of the 3 clips and slide the 3 clips to connect the 3 fuel hoses.

  5. INSTALL NO. 2 FUEL PIPE (for CCo)

    Click here

  6. INSTALL FUEL TUBE SUB-ASSEMBLY (for DPF)

    Click here

  7. INSTALL FUEL HOSE PROTECTOR (for DPF)

    Click here

  8. CONNECT ENGINE WIRE


    1. for DPF:

      Connect the engine wire with the 2 bolts and 5 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    2. for CCo:

      Connect the engine wire with the 2 bolts and 3 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    3. Install the wire harness bracket with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    4. Attach the 2 wire harness clamps.

    5. for DPF:

      Connect the glow plug connector.

    6. for CCo:

      Connect the glow plug wire harness with the nut and screw grommet.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    7. for DPF:

      Install the bolt and attach the clamp.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    8. for DPF:

      Connect the 3 connectors.

    9. Connect the pressure discharge valve connector and fuel pressure sensor connector.

  9. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  10. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  13. PERFORM REGISTRATION


    1. Perform registration of injector compensation codes.


    2. Perform registration of pilot quantity learning.


  14. BLEED AIR FROM FUEL SYSTEM

    Click here

  15. INSPECT FOR FUEL LEAK

    Click here

  16. INSTALL NO. 1 ENGINE COVER

    Click here