FUEL INJECTOR INSTALLATION

CAUTION / NOTICE / HINT

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 sub-assembly and injector assembly. If there is foreign matter, remove it before installing the injector assembly.

   • 

     *1	Copper Sealing Ring
     *a	Point Above the Copper Sealing Ring
     *b	Injector Assembly Slot End

     Make sure to replace the copper sealing ring on the injector assembly.

   • Before installing the injector assemblies to the injector assembly slots, apply a light coat of highly heat-resistant grease from above the top of the copper sealing ring to the injector assembly slot end.

   • Check the installation position of the high pressure connection.

   • Make sure to read the adjustment values each time new injector assemblies are installed.

   Tip:

   • Retighten the clamping claw rest (cylinder head cover mounting).

     Torque

     10 N*m (102 kgf*cm, 7 ft.*lbf)

   1. Install the 4 injector assemblies to the cylinder head cover sub-assembly.

   2. Step 1:

      Using an E10 "TORX" socket wrench, install the 4 clamping claws to the 4 injector assemblies with the 4 centering rings and 4 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

      Note:

      Make sure the screw centering ring is correctly positioned in order to align the clamping claw.

   3. Step 2:

      Using an E10 "TORX" socket wrench, tighten the 4 bolts.

      26 N*m

      265 kgf*cm

      19 ft.*lbf

   4. Connect the 4 injector assembly connectors.

2. CONNECT NOZZLE LEAKAGE PIPE ASSEMBLY

   1. Install 4 new sealing rings to the nozzle leakage pipe assembly.

   2. 

      *1	Sealing Ring
      *a	Leakage Line
      *b	Clip
      *c	Push down

      Connect the nozzle leakage pipe assembly to the 4 injector assemblies and push down the 4 clips to install the nozzle leakage pipe assembly.

   3. Connect the connector and attach the 2 clamps to connect the wire harness.

3. INSTALL CAMSHAFT POSITION SENSOR

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4. INSTALL INJECTION PIPE SUB-ASSEMBLY

   Note:

   • If the pressure lines are leaking after installation, they must be replaced.

   • Do not overtighten the pressure lines.

   1. Temporarily install the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies at the common rail assembly end by hand.

   2. 

      Using SST, tighten the 4 union nuts at the common rail assembly end of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies shown in the illustration.

      SST

      PZ4TB-04959-10

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Note:

      Reset SST in a timely manner to prevent bending of pressure lines.

   3. Using SST, tighten the 4 union nuts at the 4 injector assembly ends of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST

      PZ4TB-04959-10

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Note:

      Reset SST in a timely manner to prevent bending of pressure lines.

   4. Check all components of the common rail system for tightness.

5. 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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6. INSPECT FOR FUEL LEAK

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7. INSTALL ENGINE COVER

   1. Install the engine cover.

8. INSTALL NO. 1 ENGINE COVER

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9. PERFORM REGISTRATION

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