Common Rail Fuel Injection System is subject to extrembly high pressure (Approximately 1,350 bar)
Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Always pay attention to safety precaution.
Ensure the absolute cleanliness.
It is not recommended to remove the injectors without any notice.
It must be needed to clean the injector when injector is used again.
Clean the injector in vertical position in an ultra-sound bath.
If necessary, clean the injector body and sealing surface on the nozzle retaining nut also, using a fine cleaning cloth to remove any dirt residue.
Do not remove the protection caps to do that.
The nozzle-shaft must only be cleaned in an ultrasound bath and in a vertical position.
A mechanical cleaning of the nozzle-shaft by wire-brush is not permitted.
Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar)
Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Always pay attention to safety precaution.
Ensure the absolute cleanliness.
It is not recommended to remove the injectors without any notice.
Turn ignition swithc to OFF position.
Disconnect the negative battery (-) terminal and wait for about 30 seconds.
Pull off the injector electric connector (A).
Plugs must be installed and/or uninstalled only with the ignition switch turned OFF.
Do not extremely bend or squeeze the cable, do not bring them in contact with sharp edges, and also secure cables against vibrations.
Unfasten the high-pressure pipe (A) connecting the common rail and the injector.
Remove the injector return hose (A) by pulling the fixing-clip (B).
After pulling the injector plug cap (A) vertically, rotate it clockwise and remove it.
Remove injector by unscrewing injector clamp bolt (A)
Before re-installing injector, clean the cylinder head bore and sealing surface.
Insert the brush.
Clean the sealing surface and blow out.
Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar)
Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Always pay attention to safety precaution.
Ensure the absolute cleanliness.
It is not recommended to remove the injectors without any notice.
Remove the injector according to removal procedure.
Check the injector grade on top of the injector, and then replace the used injector with a new one in same grade with used one.
If it is impossible to replace the used injector with a new injector in same grade, replace it with the new one in different grade according to the table below.
Grade | X | Y | Z |
Combination 1 | 0 | 4 | 0 |
Combination 2 | 1 | 3 | 0 |
Combination 3 | 0 | 3 | 1 |
Combination 4 | 1 | 2 | 1 |
Combination 5 | 2 | 2 | 0 |
Combination 6 | 0 | 2 | 2 |
Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar)
Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Always pay attention to safety precaution.
Ensure the absolute cleanliness.
It is not recommended to remove the injectors without any notice.
Insert the new seal ring.
Whenever using the old injector again, the clamp fixing bolt and seal-ring are replaced with a new one.
Before re-installing injector, clean the cylinder head bore and sealing surface.
Insert the injector assembly into the cylinder block. At this time, do not touch the nozzle tip.
Spread oil on the injector tip and the cylinder head.
Install the injector by installing the clamp with clamp bolt.
Tightening Torques
Injector Clamp Bolt installation :
25 ~ 29 N·m (18.44 ~ 21.39 Ib·ft)
Install the injector plug cap (A) by rotating it counter clockwise.
Install the high pressure pipe (A) connecting the injector and the common rail.
Tightening Torques
High Pressure Pipe installation nut :
25 ~ 29 N·m (18.44 ~ 21.39 Ib·ft)
Connect the return hose (A) by inserting the fixing clip (B).
Afixing clip that was removed must be replaced with a new one.
Connect the injector electric connector (A).
Connect the battery (-) cable.
Start the engine and check for leakage on high pressure fuel line.
Check the fuel-system visually for any leakage. If a leakage is detected even have been used the correct torque, the component(s) must be exchanged.
COMPRESSION TEST
IDLE SPEED COMPARISON
INJECT QUANTITY COMPARISON
Connect Hi-Scan(Pro) and select "Vehicle" and "Engine Test Function".
Information for ECM version is displayed as below.
After pressing "[ENTER]" select "COMPRESSION TEST" mode and press "[ENTER]".
Set the test condition described as below screen and then, crank engine. When engine stop message being appeared, stop cranking.
Press "ANAL" and the test result is appeared.
During cranking engine does not start.
Press "AVG" and the data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
After pressing "ESC", select "IDLE SPEED COMPARISON" and press "[ENTER]".
Set the test condition described as below screen and press "[ENTER]".
The rpm data of each cylinder is appeared.
Press "AVG" and teh data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
After pressing "ESC", select "INJECT QUANTITY COMPARISON" and press "[ENTER]".
Set the test condition described as below screen and press "[ENTER]".
The data of each cylinder about RPM and compensating injection quantity is appeared.
Press "HELP" and description of the data is displayed as below.
Replace the default injector, and then repeat previous test modes to check if the injector is normal.
Refer to P0261 ~ P0272 DTC inspection procedures.
