3.
Remove the high pressure fuel pipe (B) connecting the common rail with the high pressure fuel pump.
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 regative (-) battery cable.
Disconnect the rail pressure sensor connector (A).
Remove the high pressure fuel pipe (B) connecting the common rail with the high pressure fuel pump.
Disconnect the rail pressure regulator valve connector (A).
Disconnect the return hose (C) from the common rail after removing the banjo bolt (B).
Remove the intake manifold (Refer to "Intake And Exhaust Manifold" in EM group).
Remove the high pressure fuel pipe (A) connecting the injectors with the common rail.
Remove the common rail after removing the mounting bolts (B).
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]
Common rail installation bolt:
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
High pressure fuel pipe installation nut:
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 20.1 lb-ft)
Common rail banjo installation bolt:
17.7 ~ 27.5 N.m (1.8 ~ 2.8 kgf.m, 13.0 ~ 20.3 lb-ft)
