FUEL INJECTOR INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. INSTALL NOZZLE HOLDER GASKET


    1. Install 4 new nozzle holder gaskets to the cylinder head cover sub-assembly.

  2. TEMPORARILY INSTALL INJECTOR ASSEMBLY

    Tech Tips

    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.


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

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

    3. B001CPFE01
      Text in Illustration
      *1 O-Ring

      Install a new O-ring to each injector assembly.

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

      Note

      Fit the injector assembly to the injection nozzle seats.

    5. B001CDHE02
      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 No. 1 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.

  3. TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUBASSEMBLY


    1. Temporarily install the 2 No. 2 injection pipe sub-assemblies 4 union nuts.

    2. Temporarily install the 2 No. 1 injection pipe sub-assemblies 4 union nuts.

  4. TIGHTEN INJECTOR ASSEMBLY


    1. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  5. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY


    1. B001CBVE02
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using SST, tighten the No. 1 and No. 2 injection pipe sub-assemblies 8 union nuts.

      Torque:
      Specified tightening torque
      40 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)

  6. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B001FI6E01

      Temporarily install the nozzle leakage pipe assembly and 4 new gaskets with the 4 union bolts and bolt.

    2. Tighten the 4 union bolts and bolt in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Connect the No. 5 fuel hose to the nozzle leakage pipe assembly.

  7. INSTALL HARNESS BRACKET


    1. Install the harness bracket with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  8. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket with bolt to the cylinder head cover sub-assembly.

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

    2. Connect the pressure discharge valve connector to the common rail assembly.

  9. INSTALL NO. 1 FUEL PIPE

    Click here

  10. INSTALL EGR COOLER ASSEMBLY

    Click here

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  12. PERFORM REGISTRATION


    1. Perform registration of injector compensation codes. Click here

    2. Perform registration of pilot quantity learning. Click here

  13. BLEED AIR FROM FUEL SYSTEM

    Click here

  14. INSPECT FOR FUEL LEAK

    Click here