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 injector, holder clamp and bolt to their original positions.

    • 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. B0019LX

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

    2. B001A98E02
      Text in Illustration
      *1 Fuel Injector Seal

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

    3. B0018ZYE02
      Text in Illustration
      *1 O-Ring

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

    4. 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 injector from fully seating. If so, pull out the fuel injector and reinstall it.

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

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

    7. B0018X2E02

      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


      • B0019U6E02

        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. B001A4O

      Temporarily install the common rail LH with the 2 bolts.

    9. B001AE9

      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. B001B2M

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

      Text in Illustration
      B0018FC Injector Hollow Screw
      B00199O Bolt

      Tech Tips

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

    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. B0019LX

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

    2. B001A98E02
      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. B0018ZYE02
      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 a fuel injector to the same place it was removed from.

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

    7. B0018X2E02

      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


      • B0019U6E02

        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. B001AFD

      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. B0019M6

      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
      B0018FC Injector Hollow Screw
      B00199O 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:
      48 N*m  { 489 kgf*cm, 35 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. B0019QJ

      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. B001AVA

      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. w/ Spare Tire:


      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

    Click here

  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

    Click here

  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