Installation

Fuel Injector

Installation








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

2. Apply molybdenum to the threads and seating surfaces of the clamp bolts.
3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface of the fuel injector side sleeve nuts.
6. Install the fuel injector pipes to the position shown in the illustration.
7. Use a spanner to carefully the sleeve nuts until the fuel injector pipes contact the fuel injector and common rail.
8. Tighten the fuel injection pipe clips to the specified torque.

Tightening torque: 6 N.m (5 lb ft)







9. Final tighten the injection clamp bolts to the specified torque.

Tightening torque: 30 N.m (22 lb ft)

10. Tighten the injection pipes to the specified torque.

Tightening torque: 44 N.m (33 lb ft)







11. Install the nozzle leak off pipes together with the new gaskets. Tighten the pipes to the specified torque.

Tightening torque: 12 N.m (10 lb ft)







12. Install the fuel injector harness connectors. Work from the inside out.
13. Install the harness bracket and tighten the bolts to the specified torque.

Tightening torque: 48 N.m (35 lb ft)







14. Install the fuel injector terminal nuts to the injector.
15. Alternately tighten each nut 2 or 3 turns at a time until the specified torque is reached.

Tightening torque: 2 N.m (1.7 lb ft)

CAUTION: Do not overtighten the nuts. Damage to the terminal studs will result.







16. Install the gasket to the cylinder head cover.
17. Install the cylinder head cover and tighten the bolts to the specified torque.

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







18. Install the gasket to the EGR valve and tighten the bolts to the specified torque.

Tightening torque: 24 N.m (17 lb ft)

19. Install the gasket to the EGR adapter and tighten the bolts to the specified torque.

Tightening torque: 24 N.m (17 lb ft)







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

Before Programming The Fuel Injector Flow Rate

Important: DO NOT program the fuel injector flow rate unless you are directed by a service procedure or you are directed by a service bulletin. Programming the fuel injector at any other time will not permanently correct a customers concern.

Ensure the following conditions are met before programming the ECM.
- Vehicle system voltage
- There is no charging system concern. All charging system concerns must be repaired before programming the ECM.
- Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the ECM if the battery voltage is low.
- A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or ECM damage.
- Turn OFF or disable and system that may put a load on the vehicle's battery.

- Headlights
- Room lights
- Accessory equipment
- The ignition switch is in the proper position. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so.
- All tool connections are secure.
- RS-232
- The connection at the data link connector (DLC) is secure.
- Voltage supply circuit

- DO NOT disturb the tool harness while programming. If an interruption occurs during the programming procedure, programming failure or ECM damage may occur.
- Surrounding environment
- Surrounding temperature is more than 32° (0°C) but less than 122 °F (50° C) during the programming procedure. Excessively low or high temperature may cause the programming failure or ECM damage.
- Electromagnetic interference (EMI) on the tool harness and ECM may cause the programming failure or ECM damage.

Fuel Injector Flow Rate Programming Procedure

1. Connect the scan tool to the data link connector.
2. Connect the RS-232 to the scan tool and PC.
3. Start TIS 2000 and select the Service Programming System (SPS).
4. In the "Select Diagnostic Tool and Programming Process" screen, select the following menu.
- Diagnostic tool "Pass-Thru".
- Select Programming Process "Reprogram ECU".
- ECU Location on the "Vehicle". Then, follow the SPS screen instructions.

5. Ensure that ALL programming contents are entered correctly and were programmed successfully by turning OFF the ignition for 30 seconds.
6. Using the scan tool to check each programmed fuel injector flow rate following this navigation: Diagnostics > (5) 2005 > Isuzu > NPR/NQR/NRR > F0: Powertrain > (6) 5.2L L4 Diesel > Automatic or Manual > F2: Special Functions > F5: Option Programming > F0: Injector Flow Rates.
7. Start the engine and let idle.
8. Inspect for a proper engine running condition and for no DTCs. Refer to the Diagnostic System Check - Engine Control if needed. Initial Inspection and Diagnostic Overview