FUEL INJECTOR INSTALLATION

CAUTION / NOTICE / HINT

Note


  • Always be sure to check the tightening torque.

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

  • Do not overtighten the pressure lines.

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.

    • A004R91E01

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

      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.


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

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


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

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

    3. 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. A004QS6E02
      Text in Illustration
      *1 Sealing Ring
      *2 Leakage Line
      *3 Clip
      *a Push Down

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

    3. A004Q7Y

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

  3. INSTALL CAMSHAFT POSITION SENSOR ASSEMBLY

    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. A004UCJE02

      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
      Torque:
      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
      Torque:
      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

    Click here

  7. INSTALL ENGINE COVER

  8. INSTALL NO. 1 ENGINE COVER

    Click here

  9. INSPECT FOR FUEL LEAK

    Click here