1. Component views
Injector
Part name
- Injector clamp
- Bolt
- Injector
- Sleeve nut
- Injector leak-off hose
- Eyebolt
- Fuel feed pipe
- Fuel supply pump
- Injection pipe
- Common rail (fuel rail)
Tightening torque
2: 38 N・m { 3.9 kgf・m / 28 lb・ft }
4: 35 N・m { 3.6 kgf・m / 26 lb・ft }
6: 20.2 N・m { 2.1 kgf・m / 15 lb・ft }
2. Injector installation
1) Clean the injector bracket mounting bolt holes using an air blower.
Caution
- Thoroughly clean to eliminate all sand and dust.
2) Clean the cylinder head installation surface and injector.
3) Install the gasket to the injector.
Note
- Push until seated evenly against the injector retaining nut section.
Caution
- Do not reuse the gasket.
- Do not press parts other than the gasket seal surface.
Legend
- Gasket
- Retaining nut section
- Seal surface
4) Install the injector to the cylinder head.
Caution
- Do not press the injector connector.
5) Apply engine oil to the following locations.
- Threaded section of bolt
- Seat surface of the bolt
- Washer contact surface on the injector clamp
6) Install the injector clamp to the injector.
Tightening torque: 38 N・m { 3.9 kgf・m / 28 lb・ft }
Legend
- Washer
- Injector clamp
7) Install the injector leak-off pipe to the injector.
8) Install the clips to the injector.
Caution
- Do not reuse the injector leak-off pipe or clip.
Legend
- Clip
- Injector leak-off pipe
- Injector
9) Connect the injector leak-off hose to the injector leak-off pipe and fuel leak-off pipe.
Legend
- Injector leak-off hose
10) Connect the connector to the injector.
1. When replacing the injector
Erase the old cylinder number ID code on the Injector ID Code label attached to the cylinder head cover with a black pen, etc.
Label on the cylinder head cover (Sample)
Legend
- No. 1 cylinder Injector ID Code
- No. 2 cylinder Injector ID Code
- No. 3 cylinder Injector ID Code
- No. 4 cylinder Injector ID Code
- Injector ID Code label
1) Record the Injector ID Code of the new injector.
Note
- Record the 24 characters of the injector ID plate.
The correct order of the ID codes shown in the following injector illustration is as follows.
95 04 F9 F8 F0 00 F0 E7 09 F6 F9 96
Injector (Sample)
Legend
- Injector ID Code
- Injector
3. Injection pipe installation
1) Temporarily tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the diagram.
Caution
- Do not reuse the injection pipe.
2) Final tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the diagram.
Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }
4. Intake air duct installation
1) Install the intake duct to the intake throttle valve.
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt
Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Clamp (Intake throttle side)
Clamp installation direction
Standard value
a: 45 °
2) Connect the connector to the boost pressure and CAC temperature sensor.
5. Air intake hose installation
1) Install the air intake hose to the intake air duct and intercooler.
Caution
- Align the marks on the pipe side and hose side.
Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
Legend
- Intercooler
- Air intake hose
- Intake air duct
- Clamp
6. Engine cover installation
1) Install the engine cover to the engine.
Legend
- Engine cover
7. ECM setting
1. Injector ID Code programming
Note
- If the injector has been replaced, perform the Injector ID Code programming and ECM learned value clear.
1) Connect the scan tool to the DLC.
2) Turn ON the ignition switch.
3) Select the scan tool item.
- Diagnostics > Engine > RZ4E > Programming > Injector ID Code > Program Injector ID Code
4) Program the Injector ID Code into the ECM by following the on-screen instructions.
5) After the programming is completed, turn the ignition switch OFF for 30 seconds.
2. ECM learned value clear
1) Connect the scan tool to the DLC.
2) Turn ON the ignition switch.
3) Select the scan tool item.
- Diagnostics > Engine > RZ4E > Special Function > Reset Small Fuel Injection Quantity Learning
4) Perform the ECM learned value clear by following the on-screen instructions.
5) After the learned value clear is complete, turn OFF the ignition switch for 30 seconds.