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FUEL INJECTOR(for Direct Injection) INSTALLATION

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PROCEDURE


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    INSTALL FUEL INJECTOR SEAL


    1. B00665KC04
      *a Area to be Cleaned

      Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector assembly and its grooves.

      Note:

      • Do not clean the tip of the fuel injector assembly.

      • Do not use a wire brush to clean the fuel injector assembly.

      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.

    2. B0065ANC03
      *a SST (Guide)
      *b Chamfer

      Apply engine oil to the fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the fuel injector assembly with the chamfer facing the tip of the fuel injector assembly as shown in the illustration.

      09260-39021 09261-03020
    3. B0067S5C03
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect

      Install a new fuel injector seal to SST (holder).

      09260-39021 09261-03011
      Note:

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal.

    4. B0067Z9C03
      *a SST (Holder)
      *b SST (Guide)

      Install SST (holder) with the fuel injector seal to the tip of the fuel injector assembly. Slide the fuel injector seal downward into the fuel injector assembly groove with your fingers as shown in the illustration.

      09260-39021 09261-03011 09261-03020
      Tip:

      Check that the fuel injector seal is seated in the fuel injector assembly groove as shown in the illustration.

    5. B0066V5C04
      *a SST (Guide)

      Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the fuel injector assembly groove.

      09260-39021 09261-03020
      Note:

      Be sure that the fuel injector seal is not pinched between SST (guide) and the edge of the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      Tip:

      • Set SST (guide) so that its bottom surface is flush with the fuel injector seal.

      • If it is difficult to slide SST (guide) upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.

    6. B00655HC03
      *a Normal
      *b Protruding
      *c Deformed
      *d Correct
      *e Incorrect

      After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the fuel injector assembly groove.

      Note:

      If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

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    INSTALL FUEL INJECTOR ASSEMBLY


    1. B006706C01
      *1 Fuel Injector Assembly
      *2 C-ring
      *3 Injector Vibration Insulator
      *a Taper

      Install a new injector vibration insulator and a new C-ring to the fuel injector assembly.

      Note:

      • Install the taper of the injector vibration insulator by aligning it with the taper of the fuel injector assembly.

      • Check that the C-ring is securely seated in the groove of the fuel injector assembly.

    2. B0065UXC01
      *1 No. 1 Fuel Injector Back-up Ring *2 O-ring
      *a No. 1 Fuel Injector Back-up Ring Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -

      Install a new O-ring and new No. 1 fuel injector back-up ring to the fuel injector assembly as shown in the illustration.

      Note:

      • Check that there is no foreign matter or damage on the O-ring groove of the fuel injector assembly.

      • Make sure that the No. 1 fuel injector back-up ring is installed in the correct orientation.

      • Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.

      • Check that the opening of the No. 1 fuel injector back-up ring is not overlapped or stretched as shown in the illustration.

      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

    3. B0067CGC03
      *1 Fuel Injector Assembly
      *2 No. 3 Fuel Injector Back-up Ring
      *a Notch

      With the notch of a new No. 3 fuel injector back-up ring facing downward, install the fuel injector assembly to the No. 3 fuel injector back-up ring as shown in the illustration.

      Note:

      • Make sure that the No. 3 fuel injector back-up ring is installed in the correct orientation.

      • After installing the No. 3 fuel injector back-up ring, make sure there is no damage or foreign matter.

    4. Install the nozzle holder clamp to each fuel injector assembly.

    5. B00668ZC03
      *a Protrusion
      *b Positioning Hole
      B0067U9 No Gap

      Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe LH, fuel delivery pipe RH and insert the fuel injector assembly.

      Note:

      • Make sure that there is no foreign matter or damage inside the fuel injector assembly installation holes (fuel delivery pipe LH and fuel delivery pipe RH).

      • Do not allow gasoline to get on the O-rings or inside the installation holes.

      • If it is difficult to insert the fuel injector assembly, apply new engine oil to the chamfer of the fuel injector assembly installation hole of the fuel delivery pipe LH and fuel delivery pipe RH. Be careful not to allow the fuel injector assembly to fall out of the fuel delivery pipe LH or fuel delivery pipe RH.

      • Do not tilt the fuel injector assembly when inserting it into the fuel delivery pipe LH and fuel delivery pipe RH.

      • Check that there is no gap between the fuel delivery pipe LH, fuel delivery pipe RH and the nozzle holder clamp.

      • B0066TJC02
        *a QR Code
        *b Flow Classification Number

        Make sure the 4 fuel injector assemblies have the same flow classification number 1, 2 or 3 (the number to the left of the QR code) on each bank (8 fuel injector assemblies with the same flow classification number is also okay).

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    INSTALL FUEL DELIVERY PIPE RH


    1. Apply lubricant to the fuel injector assembly installation holes of the cylinder head sub-assembly.

    2. B0065INC06
      *a Protruding enough to install nut

      Temporarily install the fuel delivery pipe RH so that the stud bolts protrude enough to install the nuts.

      Note:

      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.

      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the cylinder head sub-assembly.

      • When installing the fuel delivery pipe RH, push it in evenly without tilting it.

    3. B006676C02
      B0067U9 Bolt
      B00679M Nut

      Install the fuel delivery pipe RH by uniformly tightening the 3 bolts and 2 nuts in the order shown in the illustration.

      10 N*m 102 kgf*cm 7 ft.*lbf

    4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration again.

      29 N*m 296 kgf*cm 21 ft.*lbf
      Note:

      Make sure that there is no oil on the bolt threads and nut.

    5. Connect the 4 fuel injector assembly connectors.

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    INSTALL FUEL DELIVERY PIPE LH


    1. Apply lubricant to the fuel injector assembly installation holes of the cylinder head LH.

    2. B0065INC06
      *a Protruding enough to install nut

      Temporarily install the fuel delivery pipe LH so that the stud bolts protrude enough to install the nuts.

      Note:

      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.

      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the cylinder head LH.

      • When installing the fuel delivery pipe LH, push it in evenly without tilting it.

    3. B00653FC02
      B0067U9 Bolt
      B00679M Nut

      Install the fuel delivery pipe LH by uniformly tightening the 3 bolts and 2 nuts in the order shown in the illustration.

      10 N*m 102 kgf*cm 7 ft.*lbf

    4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration again.

      29 N*m 296 kgf*cm 21 ft.*lbf
      Note:

      Make sure that there is no oil on the bolt threads and nut.

    5. Connect the 4 fuel injector assembly connectors.

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    INSTALL CASE SEPARATOR

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    INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. Connect the No. 4 fuel pipe sub-assembly to the fuel delivery pipe LH and tighten the union nut by hand.

    2. Connect the No. 4 fuel pipe sub-assembly to the fuel delivery pipe RH and tighten the union nut by hand.

    3. B0067UGC01
      *1 Fuel Delivery Pipe LH
      *2 Fuel Delivery Pipe RH
      *3 Case Separator
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length
      *c Protector

      Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe LH side of the No. 4 fuel pipe sub-assembly.

      Specified tightening torque
      35 N*m 357 kgf*cm 26 ft.*lbf
      Tip:

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

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      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

    4. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe RH side of the No. 4 fuel pipe sub-assembly.

      Specified tightening torque
      35 N*m 357 kgf*cm 26 ft.*lbf
      Note:

      After installing the No. 4 fuel pipe sub-assembly, check that the protector of the No. 4 fuel pipe sub-assembly contacts the case separator.

      Tip:

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

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      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

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    INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH


    1. Install the No. 2 engine cover sub-assembly LH.

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    INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

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