Installation

Fuel Injector

Installation

NOTE: Install each of the fuel injectors on its original position. (the cylinder from which it was removed)

1. Install a new gasket and O-ring to each of the fuel injector clamps. Refer to the illustration.







2. Install the fuel injector clamps to the cylinder head.
3. Temporarily tighten the clamp bolts.
- Apply engine oil to the threads and seating surfaces of the clamp bolts.

4. Apply a thin coat of engine oil to the outer surface of the fuel injector side sleeve nuts.
5. Install the fuel injector pipes to the position shown in the illustration.
- Use a spanner to tighten the sleeve nuts carefully until the fuel injector pipes contact the fuel injector and the fuel rail.

6. Tighten the fuel injection pipe clips to the specified torque.

Tightening torque: 6 N.m (52 lb.in)







7. Tighten the injector clamp bolts to the specified torque.Tightening torque Injector clamp bolt: 30 N.m (22 lb.ft)
8. Tighten the injection pipe sleeve nuts to the specified torque.Tightening torque Fuel rail side: 25 N.m (18 lb.ft) Injector side: 30 N.m (22 lb.ft)







9. Install the fuel injector leak-off pipe together with the new gaskets. Tighten the pipes to the specified torque.

Tightening torque: 12 N.m (104 lb.in)







10. Install the fuel injector harness connectors. Work from the inside out.
11. Install the harness bracket and tighten the bolts to the specified torque.Tightening torque: 48 N.m (35 lb.ft)







12. Install the fuel injector terminal nuts to the injector.Tightening torque: 2 N.m (17 lb.in)

NOTE:
- Alternately tighten each nut two or three turns at a time until the specified torque is reached.
- Do not overtighten the nuts. Damage to the terminal studs will result.







13. Install the gasket to the cylinder head cover.
14. Install the cylinder head cover (1). Tighten the nuts and bolts to the specified torque.

Tightening torque: 18 N.m (13 lb.ft)







15. Install the GPCM.







16. Connect the GPCM harness connector.
17. Install the EGR cooler; 2nd.
a. Install the gaskets (1) between the EGR cooler and the duct.Move the EGR cooler duct lightly using a bar (4) etc. to make the gap between EGR cooler and duct.
b. Temporarily tighten the EGR cooler bolts (2).
c. Install the EGR cooler duct securing bolts (3).
Tightening torque: 40 N.m (30 lb.ft)

d. Tighten the EGR cooler securing bolts (2).
Tightening torque: 28 N.m (21 lb.ft)







18. Attach the engine harness connectors. Each composite connector should make a loud click when it is securely attached.

Fuel Injector Flow Rate Programming Procedure

Refer to the Fuel Injector Flow Rate Programming on the IDSS navigation: Controller Programming > ECM Programming > Injector Flow Rates.