3.
Disconnect the high pressure fuel pipe (B) connecting the injectors with the common rail.
Common Rail Fuel Injection System operates with extremely high pressure [approximately 1,800 bar (180 MPa / 26,106 psi)], 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 O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
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).
Disconnect the high pressure fuel pipe (B) connecting the injectors with the common rail.
Disconnect the retun hose (A) from the injectors.
Unscrew the clamp tightening bolt (B) and pull the injector upward.
If the injector adheres to the cylinder head, use the special Service Tool (A) [SST No. : 09351-4A300 & 09351-4A310].
Installation is reverse of removal.
After removing or replacing fuel system below, must perform fuel leakage test procedure.
(Refer to Fuel Delivery System - "Fuel Leakage Test")
Fuel tank
Fuel sender
Fuel filter
High pressure fuel pump
Injector
Common rail
Low pressure fuel line
When installing the injector, MUST REPLACE the O-ring (A) and apply a grease to that.
If re-installing injectors after removing, clean the injector bodies and contact surfaces with washers as well as the injector holes. Once the injector have been removed, the mating copper washer (B) must be replaced with new one.
Before replacing or reinstalling the injector and the washer,make sure to remove carbon deposits from the injector holes using the hole cleaning tool [SST No.:09351-27300](to ensure sealability against exhaust gas).
When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool (SST No.: 09314-27120).
Injector clamp installation bolt:
28.4 ~ 30.4 N.m (2.9 ~ 3.1 kgf.m, 21.0 ~ 22.4 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 Fuel Injection System operates with extremely high pressure [approximately 1,800 bar (180 MPa / 26,106 psi)], 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 O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
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 (20 digits) of each cylinder into ECM with scan tool.
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 (20 digit) of each cylinder into ECM with scan tool.
Turn ignition switch OFF.
Connect a 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 "Test competed" 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 (20 digits) into ECM again.
Perform "Fuel leakage test" procedure.
(Refer to Fuel Delivery System - "Fuel Leakage Test")
