GSIC - Global Service Information Center

# FUEL INJECTOR > INSTALLATION

## for Preparation Click here

1. INSTALL INJECTOR ASSEMBLY

NOTICE:

  Be sure to install the injector, holder clamp, washer and bolt in their original positions.

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

1. Apply a light amount of clean engine oil to 4 new O-rings.

1. Install the O-ring to each injector as shown in the illustration.

1. Insert the 4 injectors into the cylinder head.

   NOTICE:
   1. At this time, insert the injector until it touches the nozzle sheet surface.
   2. After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
   3. Always return an injector to the same place it was removed from.

1. Register injector compensation code (when replacing with a new injector).

1. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

   HINT:
     Apply a light amount of engine oil to the threads and under the heads of the clamp bolts.

   NOTICE:
   2. The fork portion of the nozzle holder clamp must be set to the injector.
   3. Before tightening the bolts, check that the nozzle holder clamp is set properly.
   4. To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque at following step.
   5. When tightening the bolts, pay attention not to tilt the bolt and the clamp.
   6. Do not reuse the washer.
   7. If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

1. Temporarily install the 4 injection pipes with the union nuts.

   HINT:
     To position the injectors, loosely tighten the union nut.

1. Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.
   If scratches or dents are present, replace the nozzle leakage pipe.

1. Set the leakage pipe and 5 new gaskets in place.

1. Apply a light amount of oil to the 4 hollow screws and union bolt.

1. Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

1. Tighten the 4 holder clamp bolts.

   Torque:
     22 N*m{ 224 kgf*cm , 16 ft.*lbf }

1. Tighten the 4 hollow screws in order from 1 to 4.

   Torque:
     16 N*m{ 163 kgf*cm , 12 ft.*lbf }

   NOTICE:
     If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

1. Tighten the union bolt.

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

   NOTICE:
     If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

1. Remove the 4 injection pipes.

2. CHECK FOR FUEL LEAKS

1. Check that there are no leaks from the nozzle leakage pipe connection.

   1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

      Part No.:
        23762-27010 ( No. 2 nozzle leakage pipe)
      SST
        09280-00010

      Torque:
        21 N*m{ 214 kgf*cm , 16 ft.*lbf }

   2. Apply a light amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

   3. Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 250 kPa (2.5 kgf/cm２, 35.5 psi) of pressure for 60 seconds to check that no bubbles form.

      SST
        09992-00242

      NOTICE:
        Before checking the leakage, be sure to remove the ball and spring in the check valve.

   4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

   5. Remove SST, No. 2 nozzle leakage pipe and gasket.

      SST
        09280-00010
        09992-00242

      HINT:
        Never reinstall the disassembled check valve on the engine.

3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

1. Remove any old seal packing (FIPG) material from the cylinder head.

1. Apply seal packing to the specific areas shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the belt cover within 3 minutes after applying seal packing.
   3. Do not start the engine for at least 2 hours after installing the seal packing.

1. Install the gasket and cylinder head cover with the 10 bolts and 2 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Install 4 new nozzle holder seals.

4. INSTALL INJECTION PIPE

NOTICE:

1. When replacing the injector, also replace the injection pipe.
2. Keep the joints of the injection pipe clean.

1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

1. Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

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

   HINT:
     If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

1. Using SST, tighten the injection pipe union nuts on the common rail side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Using SST, tighten the injection pipe union nuts on the injector side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Temporarily install the No. 4 injection pipe with the union nuts.

1. Install 2 new injection pipe clamps with the 2 bolts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

   NOTICE:
   1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.

1. Using SST, tighten the injection pipe union nuts on the common rail side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Using SST, tighten the injection pipe union nuts on the injector side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

5. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

1. Connect the pipe (with the 2 air hoses) and install the bolt.

   Torque:
     20 N*m{ 204 kgf*cm , 15 ft.*lbf }

1. Tighten the 2 clamps of the No. 1 and No. 2 air hoses.

   Torque:
     6.5 N*m{ 66 kgf*cm , 57 in.*lbf }

1. Connect the vacuum hose to the gas filter.

1. Connect the manifold absolute pressure sensor connector.

6. ADD FUEL

7. TIGHTEN FUEL TANK CAP ASSEMBLY

8. BLEED AIR FROM FUEL SYSTEM

1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

10. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

11. REGISTER INJECTOR COMPENSATION CODE

1. Register injector compensation code (Click here).

12. CHECK FOR FUEL LEAKS

13. CHECK FOR OIL LEAKS