FUEL INJECTOR(w/ DPF) INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.

  • When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines Click here.

PROCEDURE


  1. INSTALL FUEL INJECTOR LH

    Note


    • Be sure to install the fuel injector, holder clamp and bolt to their original positions.

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


    1. B001XP2

      Install 4 new injection nozzle seats to the cylinder head sub-assembly.

    2. B001WUCE01
      Text in Illustration
      *1 Fuel Injector Seal

      Install 4 new fuel injector seals to each fuel injector as shown in the illustration.

    3. Apply a light coat of clean engine oil to 4 new O-rings.

    4. B001Y8AE01
      Text in Illustration
      *1 O-Ring

      Install the O-rings to each fuel injector as shown in the illustration.

    5. Insert the 4 injectors into the cylinder head sub-assembly.

      Note


      • Insert the fuel injector until it touches the nozzle seat surface.

      • After installing the fuel injector to the cylinder head sub-assembly, the O-ring may prevent the fuel injector from fully seating. If so, pull out the fuel injector and reinstall it.

      • Always return an fuel injector to the same place it was removed from.

    6. For an fuel injector that has been replaced with a new fuel injector, register the injector compensation code Click here.

    7. B001YKQE01

      Temporarily install 4 new washers, 4 nozzle holder clamps and 4 new nozzle holder seals with the 4 clamp bolts.

      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *3 Nozzle Holder Seal

      Note


      • B001XUGE01

        The fork portion of the nozzle holder clamp must be set on the fuel injector.

      • Before tightening the bolts, check that the nozzle holder clamp is set properly.

      • To tighten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a later step.

      • When tightening the bolts, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Text in Illustration
      *1 Nozzle Holder Clamp
    8. B001WGJ

      Temporarily install the common rail LH with the 2 bolts.

    9. B001ZTJ

      Temporarily install 4 new injection pipes to the common rail and fuel injector.

    10. Check the nozzle leakage pipe. Check there are no scratches or dents on the union seal surfaces. If scratches or dents are present, replace the nozzle leakage pipe.

    11. B001W3V

      Temporarily install the No. 2 leakage pipe and 4 new gaskets with the 4 injector hollow screws and 2 bolts.

      Tech Tips

      To position the fuel injectors, loosely tighten the 4 hollow screws and 2 bolts.

      Text in Illustration
      B001XPG Injector Hollow Screw
      B001WGT Bolt

    12. Tighten the 4 holder clamp bolts.

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

    13. Remove the 4 injection pipes.

    14. Remove the 2 bolts and common rail LH.

  2. INSTALL NO. 2 NOZZLE LEAKAGE PIPE


    1. Tighten the 4 injector hollow screws and 2 bolts.

      Torque:
      for injector hollow screw
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL FUEL INJECTOR RH

    Note


    • Be sure to install the fuel injector, holder clamp and bolt to their original positions.

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


    1. B001XP2

      Install 4 new injection nozzle seats to the cylinder head sub-assembly.

    2. B001WUCE01
      Text in Illustration
      *1 Fuel Injector Seal

      Install 4 new fuel injector seals to each fuel injector as shown in the illustration.

    3. Apply a light coat of clean engine oil to 4 new O-rings.

    4. B001Y8AE01
      Text in Illustration
      *1 O-Ring

      Install the O-rings to each fuel injector as shown in the illustration.

    5. Insert the 4 fuel injectors into the cylinder head sub-assembly.

      Note


      • Insert the fuel injector until it touches the nozzle seat surface.

      • After installing the fuel injector to the cylinder head sub-assembly, the O-ring may prevent the fuel injector from fully seating. If so, pull out the fuel injector and reinstall it.

      • Always return an fuel injector to the same place it was removed from.

    6. For an fuel injector that has been replaced with a new injector, register the injector compensation code Click here.

    7. B001YKQE01

      Temporarily install 4 new washers, 4 nozzle holder clamps and 4 new nozzle holder seals with the 4 clamp bolts.

      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *3 Nozzle Holder Seal

      Note


      • B001XUGE01

        The fork portion of the nozzle holder clamp must be set on the fuel injector.

      • Before tightening the bolts, check that the nozzle holder clamp is set properly.

      • To tighten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a later step.

      • When tightening the bolts, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Text in Illustration
      *1 Nozzle Holder Clamp
    8. B001VYV

      Temporarily install 4 new injection pipes to the common rail and fuel injector.

    9. Check the nozzle leakage pipe. Check that there are no scratches or dents on the union seal surfaces. If scratches or dents are present, replace the nozzle leakage pipe.

    10. B001YFK

      Temporarily install the No. 1 leakage pipe and 4 new gaskets with the 4 injector hollow screws and union bolt.

      Tech Tips

      To position the injectors, loosely tighten the 4 hollow screws and union bolt.

      Text in Illustration
      B001XPG Injector Hollow Screw
      B001WGT Union Bolt

    11. Tighten the 4 holder clamp bolts.

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

    12. Remove the 4 injection pipes.

  4. INSTALL NO. 1 NOZZLE LEAKAGE PIPE


    1. Tighten the union bolt and 4 injector hollow screws.

      Torque:
      for union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for injector hollow screw
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Install the fuel tube and No. 1 nozzle leakage pipe with the check valve and new gasket.

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

  5. INSTALL NO. 3 NOZZLE LEAKAGE PIPE

    Click here

  6. CONNECT CONNECTING WIRE

    Click here

  7. INSTALL CYLINDER HEAD COVER INSULATOR RH

  8. INSTALL NO. 2 ENGINE WIRE

    Click here

  9. INSTALL INJECTION PIPE RH

    Click here

  10. INSTALL NO. 1 FUEL INJECTOR PROTECTOR


    1. B00206F

      Install the No. 1 fuel injector protector with the bolt.

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

      Tech Tips

      Press the ventilation hose clip against the No. 1 fuel injector protector as shown in the illustration.

  11. INSTALL CYLINDER HEAD COVER SILENCER RH


    1. Install the cylinder head cover silencer with the 4 bolts.

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

  12. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  13. INSTALL COMMON RAIL ASSEMBLY LH

    Click here

  14. INSTALL CYLINDER HEAD COVER INSULATOR LH

  15. INSTALL INJECTION PIPE LH

    Click here

  16. INSTALL NO. 2 FUEL INJECTOR PROTECTOR


    1. B001ZK2

      Install the No. 2 fuel injector protector with the bolt.

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

      Tech Tips

      Press the ventilation hose clip against the No. 2 fuel injector protector as shown in the illustration.

    2. Attach the hose clamp.

  17. INSTALL NO. 4 NOZZLE LEAKAGE PIPE

    Click here

  18. INSTALL CYLINDER HEAD COVER SILENCER LH


    1. Install the cylinder head cover silencer with the 4 bolts.

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

  19. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the vacuum transmitting pipe with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Connect the 2 vacuum hoses.

  20. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for Engine Mounting)


    1. Install the vacuum switching valve with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Connect the 2 vacuum hoses.

  21. INSTALL NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  22. CONNECT ENGINE WIRE

    Click here

  23. INSTALL NO. 4 WATER BY-PASS PIPE

    Click here

  24. INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  25. CONNECT FUEL HOSE

  26. INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  27. INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  28. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  29. INSTALL NO. 4 AIR TUBE

    Click here

  30. INSTALL NO. 2 AIR HOSE

    Click here

  31. INSTALL NO. 3 AIR TUBE

    Click here

  32. INSTALL NO. 1 AIR HOSE

    Click here

  33. INSTALL INTAKE AIR CONNECTOR

    Click here

  34. TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

    Click here

  35. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  36. INSTALL DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  37. INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  38. INSTALL NO. 1 GAS FILTER

    Click here

  39. INSTALL AIR TUBE SUB-ASSEMBLY LH

    Click here

  40. INSTALL DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  41. INSTALL AIR TUBE SUB-ASSEMBLY RH

    Click here

  42. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  43. CONNECT WATER HOSE SUB-ASSEMBLY

  44. INSTALL INTERCOOLER ASSEMBLY

    Click here

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.

  46. REGISTER INJECTOR COMPENSATION CODE

    Click here

  47. ADD ENGINE COOLANT

    Click here

  48. INSPECT FOR COOLANT LEAK

    Click here

  49. INSPECT FOR FUEL LEAK

    Click here

  50. INSPECT FOR OIL LEAK

    Click here

  51. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  52. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  53. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  54. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here