FUEL INJECTION NOZZLE INSTALLATION

PROCEDURE


  1. INSTALL NOZZLE HOLDER AND NOZZLE SET


    1. Install 4 new injection nozzle seat gaskets and the 4 injection nozzle seats to the injection nozzle holes of the cylinder head sub-assembly.

    2. B003QONN01

      Using SST, install the 4 nozzle holder and nozzle sets.

      SST
      09268-64010   ( 09268-64020 )
      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

      Note


      • Overtightening could cause nozzle deformation and needle adhesion or other defects.

      • When installing the injection nozzle, never tighten the nozzle holder body. Tighten the retaining nut section.

      Tech Tips

      Arrange the nozzle holder and nozzle sets in correct order.

  2. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Install 4 new ring packing washers and the nozzle leakage pipe assembly with the 4 ring packing setting nuts.

      Torque:
      29.5 N*m  { 301 kgf*cm, 22 ft.*lbf }

    2. Connect the fuel hose to the nozzle leakage pipe assembly, and slide the clamp to secure the hose.

  3. INSTALL NO. 1 GLOW PLUG CONNECTOR

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  4. INSTALL INJECTION PIPE SUB-ASSEMBLY


    1. B003N95C06
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, install the 4 injection pipe sub-assemblies to the nozzle holder and nozzle set and injection pump assembly with the union nuts.

      Torque:
      Specified tightening torque
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Tech Tips


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

        Click here

      • When using a union nut wrench (fulcrum length of 30 mm (1.181 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 21 N*m (214 kgf*cm, 15 ft.*lbf)

    2. Install the 2 injection pipe clamps with the 2 nuts.

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

  5. INSTALL VENTURI ASSEMBLY

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  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  7. BLEED AIR FROM FUEL SYSTEM


    1. Move the hand pump on the upper part of the fuel filter assembly up and down and fill the injection pump assembly and fuel system with fuel.

    2. Using a 17 mm union nut wrench, loosen one of the union nuts (on the nozzle holder and nozzle set side).

    3. Crank the engine until fuel comes out from the union nut connection (on the nozzle holder and nozzle set side).

    4. B003N95C06
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the union nut (on the nozzle holder and nozzle set side).

      Torque:
      Specified tightening torque
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Tech Tips


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

        Click here

      • When using a union nut wrench (fulcrum length of 30 mm (1.181 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 21 N*m (214 kgf*cm, 15 ft.*lbf)

    5. Perform the procedures above for each injection pipe sub-assembly.

  8. INSPECT FOR FUEL LEAK

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