Fuel Injector - Installation

INSTALLATION

1. Inspect fuel injector :
a. Look for burrs on injector inlet.
b. Check nozzle holes for hole erosion or plugging.
c. Inspect end of nozzle for burrs or rough machine marks.
d. Look for cracks at nozzle end.
e. If any of these conditions occur, replace injector.
2. Record six-digit alphanumeric correction code located on the side of injector.
3. Inspect high-pressure fuel injector connector for :
a. Damaged tip.
b. Loose of missing alignment pin.
c. Cut or missing O-ring.
4. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.










5. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (.060")
6. Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation.
7. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore.





8. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector.





9. Tightening Sequence:
a. Install fuel injector hold-down clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 5 Nm (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered.
b. After tightening, relieve bolt torque, but leave both bolts threaded in place.
c. Install high-pressure connector (13) and retaining nut (12). Do a preliminary tightening of nut (12) to 15 Nm (133 in. lbs.).
d. Alternately tighten injector hold-down bolts to 10 Nm (89 in. lbs.).
e. Do a final tightening of the high-pressure connector and retaining nut (12). Tighten to 50 Nm (37 ft. lbs.).
10. Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components.





11. Install the necessary rocker housing mounting bolt (1) and tighten to 24 Nm (18 ft. lbs).




12. Install integrated gasket (2).










13. Connect fuel injector solenoid wires and nuts (1) to top of injectors. Tighten connector nuts to 1.25 Nm (11 in. lbs.). Be very careful not to overtighten these nuts as damage to fuel injector will occur.
14. Install the intake and exhaust rocker arm assembly. Valve Rocker Arm - Installation
15. Set exhaust valve lash. Procedures. Refer to the Diesel Engine.
16. Install fuel connector tube nut at cylinder head and tighten to 50 Nm (37 ft. lbs.). Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting.Fuel Tube(s) - Installation
17. Install valve cover. Cylinder Head Cover(s) - Installation
18. Install breather assembly.

FUEL INJECTOR ID CORRECTION CODES:




Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Powertrain Control Module (PCM) using a diagnostic scan tool. In addition, if a new PCM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new PCM.

1. Connect negative battery cables to both batteries.
2. Programming Fuel Injector Correction Code:
- Turn ignition switch "ON".

- Using a diagnostic scan tool, select ECU View> PCM > MISCELLANEOUS FUNCTIONS.

- Select Injector Quantity Adjustments and click Start.

- Choose appropriate cylinder number and click next.

- Click on Show Keyboard. NOTE: A fault code will be set if incorrect serialization codes have been inputted.

- Input six-digit Injector Correction Code and click enter.

- Review code as it was typed, then click Next if correct, or edit if necessary.

- Repeat the preceding steps for other cylinders if necessary.

- Once all fuel injector correction codes are entered, cycle the ignition to complete.