4.
Unfasten the high-pressure pipe (B) connecting the common rail and the injector.
Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,600 bar)
Never perform any work on injection system wth engine running or within 30 seconds after the engine stops.
Always pay attention to safety precaution.
Ensure the absolute cleanliness.
It is not recommanded 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 ultra-sound 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 1,600 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 switch 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 (B) connecting the common rail and the injector.
Remove the injector return hose (C) by pulling the fixing-clip (D) and unscrew the injector fixing bolt(E).
Pull the injector assembly.
When pulling the injector, pull the injector upright so that the nozzle needle cannot be scratched or damaged.
When the injector is stuck on cylinder head, pull it out with SST (09351-4A200, 09351-2A100 ).
When exchanging injectors be sure to input injector data(7 digits) of new one into the ECM using a Hi-Scan(Pro).
Remove the injector according to removal procedure.
Check the class of injector, and then replace the used injector with the new one.
Check injector data (7 digits) of new injector.
Using Hi-Scan(Pro), input the injector data(7 digits) into ECM as next procedure.
When displaying "WRITING FAIL" ON Hi-scan(Pro), input injector data (7digits) of each cylinder into a new ECM again as priow procedure.
If the glow lamp is flashed and DTC P1586 is detected ignition switch ON, take proper steps refering to "P1586 DTC Troubleshooting procedure".
Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,600 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 used 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.
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): 27.5 ~ 29.4 N·m (20.3 ~ 21.7 lbf·ft)
After screwing thr high pressure pipe installation nuts by hand, tighten them at accurate torque using special service tools (09354-27110, 09314-27130).
Tightening Torque (High Pressure Pipe installation nut): 24.5 ~ 28.4 N·m (18.1 ~ 21.0 lbf·ft)
Connect the return hose (A) by inserting the fixing clip (B).
Do not reuse a fixing clip.
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.
