As the Piezo-Injector operates under maximum DC 200V, there may be a risk of an electric shock caused by shorted control line etc. So when repairing the injector or its wiring, disconnect the battery negative (-) terminal from the battery and wait for about 30 seconds.
Common Rail Fuel Injection System operates with extremely high pressure (approximately 1,800bar), so never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Keep cleanly the parts and the working area.
Pay attention to a foreign substance.
Just before installing injector, tube or hose, remove the protect-cap attached on them.
Do not remove injector except for special case.
When installing Injector
Wash the contact area of the injector and replace the gasket with a new one.
To protect damage caused by shock, vertically insert the injector into the cylinder head.
Clean the connecting surface of the injector gasket on the cylinder head before installing the injector.
When installing High Pressure Fuel Pipe
Do not use again the used high pressure fuel pipe.
Install the flange nut correctly.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
Disconnect the injector connector (A) and the injector return line (B).
Remove the high pressure fuel pipe (C).
Before connecting the injector return line or after disconnecting the injector return line, check that the plug bush was completely raised from the plug. Otherwise fuel will leak around the injector’s nipple because of broken plug.
[DISCONNECTION-INJECTOR RETURN LINE]
Pull the plug bush upward with the plug grip pressed.
Seize the return line on both sides of the plug, and then disconnect the plug upward from the injector nipple.
Unscrew the injector clamp bolt (A), and then remove the injector (B).
If the injector adheres to the cylinder head, use the Special Service Tool (SST No.: 09351-4A300, 09351-4A310).
Installation is reverse of removal.
When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool [SST No.: 09314-3A000].
When installing the high pressure fuel pipe connecting the common rail and injector, follow the below procedure.
Temporarily install the nuts on common rail and injector
Install the injector side and common rail side sequentially
Injector clamp installation bolt: 29.4 ~ 33.4 N.m (3.0 ~ 3.4 kgf.m, 27.1 ~ 24.6 lb-ft)
High pressure fuel pipe installation nut: 24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 21.0 lb-ft)
[CONNECTION-INJECTOR RETURN LINE]
With the plug bush fully raised, vertically install the plug to the injector nipple until "Click" sound generates.
Press the plug bush downward until "Click" sound generates.
As the Piezo-Injector operates under maximum DC 200V, there may be a risk of an electric shock caused by shorted control line etc. So when repairing the injector or its wiring, disconnect the battery negative (-) terminal from the battery and wait for about 30 seconds.
Common Rail Fuel Injection System operates with extremely high pressure (approximately 1,800bar), so never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Keep cleanly the parts and the working area.
Pay attention to a foreign substance.
Just before installing injector, tube or hose, remove the protect-cap attached on them.
Do not remove injector except for special case.
When installing Injector
Wash the contact area of the injector and replace the gasket with a new one.
To protect damage caused by shock, vertically insert the injector into the cylinder head.
Clean the connecting surface of the injector gasket on the cylinder head before installing the injector.
When installing High Pressure Fuel Pipe
Do not use again the used high pressure fuel pipe.
Install the flange nut correctly.
After replacing injector, MUST input the injector specific data (7 digits) of each cylinder into ECM with the GDS.
Remove the injector (Refer to "REMOVAL" procedure).
Install the injector (Refer to "INSTALLATION" procedure).
Perform "Injector Specific Data Input" procedure (Refer to "INJECTOR SPECIFIC DATA INPUT" procedure).
After replacing injector, MUST input the injector specific data (7 digit) of each cylinder into ECM with the GDS.
Turn ignition switch OFF.
Connect the GDS to Data Link Connector (DLC).
Turn ignition switch ON.
Select "Vehicle, Model year, Engine, System".
Select "Vehicle S/W Management".
Select "injector Specific Data".
Perform the procedure in accordance with the message.
After selecting "OK" on the "Writing success" message, turn ignition switch OFF.
In about 10 seconds, turn ignition switch ON and recheck the injector specific data memorized in the ECM.
In case of failure, input the injector specific data (7 digits) into ECM again.
Turn ignition switch OFF.
Connect the GDS to Data Link Connector (DLC).
Turn ignition switch ON.
Select "Vehicle, Model year, Engine, System".
Select "Vehicle S/W Management".
Select "Engine Test Function".
Select "Compression Test".
Perform the test in accordance with the message.
If a cylinder's engine speed is higher than the other cylinders, the cylinder's compression pressure is low.
Turn ignition switch OFF.
Connect the GDS to Data Link Connector (DLC).
Turn ignition switch ON.
Select "Vehicle, Model year, Engine, System".
Select "Vehicle S/W Management".
Select "Engine Test Function".
Select "Idle Speed Comparision".
Perform the test in accordance with the message.
Turn ignition switch OFF.
Connect the GDS to Data Link Connector (DLC).
Turn ignition switch ON.
Select "Vehicle, Model year, Engine, System".
Select "Vehicle S/W Management".
Select "Engine Test Function".
Select "Injection Quantity Comparison".
Perform the test in accordance with the message.
