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FUEL INJECTOR INSTALLATION

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CAUTION / NOTICE / HINT

Note:

  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, 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.

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PROCEDURE


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    INSTALL NOZZLE HOLDER GASKET


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

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    TEMPORARILY INSTALL INJECTOR ASSEMBLY

    Note:

    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. B0024J8C01
      *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. B0025AZC01
      *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.

      Tip:

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

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    TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY


    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.

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    TIGHTEN INJECTOR ASSEMBLY


    1. Tighten the 4 nozzle holder clamp bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
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    TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY


    1. B00261FC01
      *a Torque Wrench Fulcrum Length

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

      09245-11010
      Specified tightening torque
      40 N*m 408 kgf*cm 30 ft.*lbf
      Tip:

      • 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)

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    INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B0027M9E01

      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.

      12 N*m 122 kgf*cm 9 ft.*lbf

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

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    INSTALL HARNESS BRACKET


    1. Install the harness bracket with the bolt.

      8.4 N*m 86 kgf*cm 74 in.*lbf
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    INSTALL WIRING HARNESS CLAMP BRACKET


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

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

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

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    INSTALL NO. 1 FUEL PIPE (w/ DPF)

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    INSTALL EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

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    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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    PERFORM REGISTRATION


    1. Perform registration of injector compensation codes.

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    2. Perform registration of pilot quantity learning.

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    BLEED AIR FROM FUEL SYSTEM

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    INSPECT FOR FUEL LEAK

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