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.
Disconnect the injector 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.
Disconnect the high pressure pipe (A) connecting the injectors with the common rail.
After removing the clip (B), disconnect the retun hose (C) from the injectors and unscrew the clamp tightening bolt (D).
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 (SST No.: 09351-4A300).
Install the injector according to the reverse order of REMOVAL procedure.
When installing the injector, MUST REPLACE the O-ring (A) and apply a grease to that.
When installing the high pressure pipe, apply the specified tightening torques to the flange nuts of the injectors and the common rail side with SST (Refer to below table).
Item | Dimension | SST No. |
Flange Nut (Injector Side) | 14 mm (0.551 in) | 09314-27110 |
Flange Nut (Common Rail Side) | 17 mm (0.669 in) | 09314-27120 |
· Injector clamp installation bolts: 28.4 ~ 30.4 N·m
(2.9 ~ 3.1 kgf·m, 21 ~ 22.4 lbf·ft)
· High pressure pipe flange nuts (Injectors ↔ Common Rail):
24.5 ~ 28.4 N·m(2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
After replacing an ECM, MUST input the injector data (7 digit) of each cylinder into a new ECM.
Replace the injector with a new one according to the "REMOVAL" and "INSTALLATION" procedures.
Connect a scan tool to Data Link Connector (DLC) and turn ignition switch on.
Select "ENGINE CONTROL".
Select "AUTO SELECTION MODE" or "MANUAL SELECTION MODE".
Select "1.6L VGT DIESEL" in case of "MANUAL SELECTION MODE".
Select "INJECTOR CORRECTION".
Press "ENTER" key.
Input the injector data (7 digit) written on the top of each inejctor with function keys ([F1] ~ [F6]) and number keys.
When "WRITING FAIL" is displayed on the scan tool, input injector data (7 digits) of each cylinder into a new ECM again as prior procedure.
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 the data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
After pressing "ESC", select "INJECTOR QUANTITY COMPARISON" and press "[ENTER]".
Set the test condition described as below screen and press "[ENTER]".
The data od 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.
Turn ignition switch "OFF".
Disconnect injector connector.
Measure resistance between the terminals 1 and 2 of injector connector.
Resistance : 0.215 ~ 0.295Ω [20 ~ 70℃(68 ~ 158℉)]
