FUEL INJECTOR INSTALLATION

CAUTION / NOTICE / HINT

Note

When replacing the injector assemblies (including exchanging the injector assemblies between the cylinders), it is necessary to replace the injection pipe sub-assemblies with new ones.

Tech Tips

After replacing any of the injector assemblies, perform both the "Injector Compensation" and the "Pilot Quantity Learning Values Reset" functions using the GTS.

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PROCEDURE


  1. INSTALL INJECTOR ASSEMBLY

    Note

    Before installing the injector assembly, check for carbon, foreign matter, etc. on the sealing surfaces of the cylinder head and injector assembly. Clean them if necessary.


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

    2. A00Y5TSC01
      *1 O-ring

      Install new O-rings to each injector assembly.

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

    4. Install the 4 injector assemblies to the cylinder head.

      Note

      Fit the injector assemblies to the injection nozzle seats.

  2. INSTALL NO. 1 NOZZLE HOLDER CLAMP


    1. A00YA7EC01
      *1 Washer

      Install the No. 1 nozzle holder clamps and washers as shown in the illustration.

      Note

      Be careful of the mounting orientation (beveled edge) of the washer.

    2. Temporarily install the nozzle holder clamp bolts.

      Note

      When temporarily installing the nozzle holder clamps and No. 1 nozzle holder clamp bolts, be careful not to position them at an angle.

      Tech Tips

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

    3. A00YB6Y

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

    4. A00YAKJ

      Temporarily install the injection pipe sub-assembly.

    5. Tighten the 4 nozzle holder clamp bolts.

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

  3. 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:
      20.5 N*m  { 209 kgf*cm, 15 ft.*lbf }

  4. INSTALL INJECTION PIPE SUB-ASSEMBLY


    1. A00Y8H7

      Using a 14 mm union nut wrench, tighten the 4 nuts at the common rail assembly end of the injection pipe sub-assemblies.

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

      Note

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

      Click here

    2. Using a 14 mm union nut wrench, tighten the 4 nuts at the injector assembly end of the injection pipe sub-assemblies.

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

      Note

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut 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 }

  5. INSTALL NO. 2 NOZZLE LEAKAGE PIPE


    1. A00Y8NYC01
      *1 Check Valve

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

    2. Tighten the check valve.

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

    3. Tighten the bolt.

      Torque:
      31.5 N*m  { 321 kgf*cm, 23 ft.*lbf }
    4. A00YA2Q

      Connect the 3 fuel hoses with the 3 clips.

  6. INSTALL FUEL TUBE SUB-ASSEMBLY

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  7. INSTALL FUEL HOSE PROTECTOR

    Click here

  8. CONNECT ENGINE WIRE


    1. Connect the engine wire with the bolt and 5 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Install the 2 wire harness brackets with the 2 bolts.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    3. Engage the 2 wire harness clamps.

    4. Connect the glow plug connector.

    5. Connect the connector to the pressure control valve.

    6. Connect the connector to the fuel pressure sensor.

    7. A00YAI7

      Connect the 3 connectors.

    8. Connect the 4 connectors to the 4 injector assemblies.

  9. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  10. INSTALL AIR CLEANER CAP SUB-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 AND INITIALIZATION


    1. Perform registration of injector assembly compensation codes.

      Click here

    2. Perform registration of pilot quantity learning.

      Click here

  13. BLEED AIR FROM FUEL SYSTEM

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  14. INSPECT FOR FUEL LEAK

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  15. INSTALL NO. 1 ENGINE COVER

    Click here

  16. INSTALL OUTER COWL TOP PANEL

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  17. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

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  18. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  19. INSTALL WATER GUARD PLATE LH

    Click here

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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