Fuel Injector Installation

Install 4 new nozzle seats to the cylinder head.

Install new O-rings to each injector.

Apply a light coat of engine oil to the O-rings on each injector.

Install the 4 injectors to the cylinder head.

NOTICE:

Fit the injectors to the nozzle seats.

Install the nozzle holder clamps and washers as shown in the illustration.

Temporarily install the nozzle holder clamp bolts.

NOTICE:

1. Pay attention to the mounting direction (bevelled edge) of the washer.
   
2. When temporarily attaching the nozzle holder clamp and the nozzle holder clamp bolt, be careful not to position them at an angle.
   

HINT:

Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

Temporarily install the 4 clamps to the cylinder head with the 4 bolts.

Using a hexagon socket wrench, tighten the 4 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Temporarily install the No. 1, No. 2, No. 3 and No. 4 injection pipes.

Temporarily install 4 new gaskets, and No. 1 leakage pipe with the 4 union bolts.

Tighten the 4 nozzle holder clamp bolts.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Remove the No. 1, No. 2, No. 3 and No. 4 injection pipes.

Temporarily install a new gasket, fuel check valve and bolt.

Tighten the 4 union bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Tighten the fuel check valve and bolt.

Torque:

For fuel check valve:

32 N*m{321 kgf*cm, 23 ft.*lbf}

For bolt:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Temporarily install the 2 fuel inlet pipes, 2 injection pipe clamps and the bolt.

Using the SST, first tighten the nut at the common rail end of the fuel inlet pipe.

SST

09023-38401

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

HINT:

1. Use of the proper SST is necessary to ensure that the correct torque is applied to the fuel inlet pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Using the SST, tighten the nut at the fuel supply pump of the fuel inlet pipe.

SST

09023-38401

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

HINT:

1. Use of the proper SST is necessary to ensure that the correct torque is applied to the fuel inlet pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Tighten the 2 injection pipe clamps with the bolt.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the engine wire harness to the cylinder head cover.

Connect the 2 harness clamps and the 4 injector connectors.

Install the 2 nuts.

Torque:

2.2 N*m{22 kgf*cm, 19 in.*lbf}

Temporarily install the injection pipe.

Using the SST, first tighten the nut at the common rail end of the injection pipe.

SST

09023-38401

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

HINT:

1. Use of the proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Using the SST, tighten the nut at the injector end of the injection pipe.

SST

09023-38401

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

HINT:

1. Use of the proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Temporarily install the 3 injection pipes and the 4 injection pipe clamps with the 2 bolts.

Using the SST, first tighten the nut at the common rail end of the injection pipe.

SST

09023-38401

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

HINT:

1. Use of the proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Using the SST, tighten the nut at the injector end of the injection pipe.

SST

09023-38401

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

HINT:

1. Use of the proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Tighten the 4 injection pipe clamps with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the No. 1 intake manifold insulator.

Install the wire harness clamp bracket with the 2 bolts.

Connect the 5 wire harness clamps.

Connect the wire harness clamp.

Install the No. 1 fuel pipe with the 2 bolts.

Connect the 2 fuel hoses and 2 clips.

PERFORM ACTIVE TEST

1. Connect the intelligent tester to the DLC3.
   

2. Turn the engine switch ON (IG).
   

3. Turn the intelligent tester ON.
   

4. Enter the following menus: Powertrain / ENGINE / Active Test.
   

5. Perform the Active Test.
   
   

   Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
   Test the Fuel Leak	Pressurize common rail internal fuel pressure, and check for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when "Start" is selected Above conditions to be maintained while "Start" is selected

Install the No. 1 engine cover.

Perform initialization procedure (Click here).

HINT:

Some vehicle systems require initialization after reconnecting the negative battery terminal.