note
When installing the injector, the o-ring (A) must be replaced and greased.
After removing or replacing fuel system below, the fuel leakage test procedure must be performed. (Refer to "Fuel leak test" in this group.)
Fuel tank
Fuel sender
Fuel filter
High pressure fuel pump
Injector
Common rail
Low pressure fuel line
When installing the injector, the o-ring (A) must be replaced and greased.
Common Rail Fuel Injection System operates with extremely high pressure (approximately 2,000bar), so do not perform any work on injection system with engine running or within 30 seconds after the engine stops.
Keep clean the components of common rail system and the working area.
Keep away from foreign substances when installing the fuel supply system.
Remove protective cap attached to the injector, tube or hose just before installation to prevent influx of foreign substances.
Do not remove injector except in special case.
When installing the injector
- Clean the contact area of the injector and replace the gasket with a new one.
- Vertically insert the injector into the cylinder head to prevent the damage caused by shock.
- Clean the surface under the injector gasket of the cylinder head before installing the injector.
When installing High Pressure Fuel Pipe
- Install the flange nut correctly.
- Do not reuse high pressure fuel pipes. Always use a new one.
When removing / installing the injector return line
- Insert the connector only in the unlock status.
- Insert the connector by hand. Do not use a tool.
Install the injector to the specified torque.
If the injector is dropped by mistake, check if there is no problem.
Install the injector on each cylinder.
Install the injector clamp.
Fasten the clamp mounting bolt lightly.
Tighten the flange nuts on both side.
Tighten the injector clamp mounting bolt (A) to the specified torque.
Injector clamp mounting bolt :
28.4 ~ 30.4 N.m (2.9 ~ 3.1 kgf.m, 21.0 ~ 22.4 lb-ft)
Be sure to use torque wrench.
Tighten the flange nut (A) on the injector side to the specified torque.
High pressure fuel pipe flange nut :
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 21.0 lb-ft)
Be sure to use torque wrench.
Tighten the flange nut (A) on the common rail side to the specified torque.
High pressure fuel pipe flange nut :
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 21.0 lb-ft)
When installing the high pressure fuel pipe, tighten the nut to the specified torque using the SST 09314-3A000.
Install the injector return line (A).
Check if the locker (A) is unlocked.
Insert the connector by hand.
Rotate the locker 90˚ clockwise.
Check if the locker (A) is locked correctly.
Connect the injector connector.
Connect the battery negative (-) terminal.
