Injectors

2010 > D 2.
5 TCI-A > Fuel System > Engine Control System > Injector > Repair procedures
Removal
● Common Rail Fuel Injection System operates with extremely high pressure (approximately
1,600bar), so never perform any work on injection system with engine running or within 30
seconds after the engine stops.
● Keep cleanly the parts and the working area.
● Pay attention to a foreign substance.
● Just before installing injector, tube or hose, remove the protect-cap attached on them.
● Do not remove injector except for special case.
● When installing Injector
- Wash the contact area of the injector and replace the O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
● When installing High Pressure Fuel Pipe
- Do not use again the used high pressure fuel pipe.
- Install the flange nut correctly.
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the injector connector (A).
3. After removing the clip (B), disconnect the retun tube (C) from the injectors.
4. Disconnect the high pressure fuel pipe (D) connecting the injectors with the common rail.
5. Unscrew the clamp tightening bolt (A) and pull the injector upward.
1/12
2010 > D 2.5 TCI-A > Fuel System > Engine Control System > Injector > Repair procedures
If the injector adheres to the cylinder head, use the special Service Tool (SST No. : 09351-
4A300)
Installation
1. Installation is reverse of removal.
When installing the injector, MUST REPLACE the O-ring (A) and apply a grease to that.
When installing the high pressure fuel pipe, apply the specified tightening torques with the
special service tool (Refer to below table).
Item Dimension SST No.

Flange Nut
14mm (0.551in) 09314-27110
(Injector Side)
Flange Nut
17mm (0.669in) 09314-27120
(Common Rail Side)
· Injector clamp installation bolt:

27.5 ~ 33.4N.m (2.8 ~ 3.4kgf.m, 20.3 ~ 24.6lb-ft)
· High pressure fuel pipe installation nut:
24.5 ~ 28.4N.m (2.5 ~ 2.9kgf.m, 18.1 ~ 20.1lb-ft)
Replacement
● Common Rail Fuel Injection System operates with extremely high pressure (approximately
1,600bar), so never perform any work on injection system with engine running or within 30
seconds after the engine stops.
● Keep cleanly the parts and the working area.
● Pay attention to a foreign substance.
● Just before installing injector, tube or hose, remove the protect-cap attached on them.
2/12
● Do not remove injector except for special case.

● When installing Injector
- Wash the contact area of the injector and replace the O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
● When installing High Pressure Fuel Pipe
- Do not use again the used high pressure fuel pipe.
- Install the flange nut correctly.
After replacing injector, MUST input the injector specific data (7 digits) of each cylinder into ECM
with scan tool.
1. Remove the injector (Refer to "Removal" procedure).

2. Install the injector (Refer to "Installation" procedure).
3. Perform "Injector Specific Data Input" procedure (Refer to "Injector Specific Data Input" procedure).
Injector Specific Data Input
After replacing injector, MUST input the injector specific data (7 digit) of each cylinder into ECM
with scan tool.
1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).
3. Turn ignition switch ON.
4. Select "INJECTOR SPECIFIC DATA".
3/12
5. Confirm the message, and then press "ENTER" key.
6. Input the injector data (7 digit), and then press "ENTER" key.
7. After comfirming the "Complete" message, turn ignition switch OFF.
8. In about 10 seconds, turn ignition switch ON and check the injector specific data memorized in the
4/12
ECM.
In case of failure, input the injector specific data (7 digits) into ECM again.
Inspection
[Compression Test]
4. Select "ENGINE TEST FUNCTION".
6. Select "COMPRESSION TEST".
5/12
Perform the test in accordance with the message.
7.
6/12
If a cylinder's engine speed is higher than the other cylinders, the cylinder's compression
pressure is low.
[Idle Speed Comparison]

7/12
6. Select "IDLE SPEED COMPARISON".
7. Perform the test in accordance with the message.
8/12
The injector in cylinder with significantly high (low) idle speed injects more (less) quantity than
the other injectors.
[Injection Quantity Comparison]

9/12
6. Select "INJECTION QUANTITY COMPARISON".
7. Perform the test in accordance with the message.
10/12
* (+) correction value: Injection quantity is less than the others.

* (-) correction value: Injection quantity is more than the others.
11/12
* Very high correction value: The injector may have any fault. At this time, replace the injector
with a new one and perform these tests again.
12/12

Injectors

Uploaded by

Copyright:

Available Formats

Injectors

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Injectors

Uploaded by

Copyright:

Available Formats

2010 > D 2.

Item Dimension SST No.

· Injector clamp installation bolt:

● Do not remove injector except for special case.

1. Remove the injector (Refer to "Removal" procedure).

1. Turn ignition switch OFF.

5. Confirm the message, and then press "ENTER" key.

7. After comfirming the "Complete" message, turn ignition switch OFF.

5. Confirm the message, and then press "ENTER" key.

6. Select "COMPRESSION TEST".

Perform the test in accordance with the message.

[Idle Speed Comparison]

5. Confirm the message, and then press "ENTER" key.

6. Select "IDLE SPEED COMPARISON".

7. Perform the test in accordance with the message.

[Injection Quantity Comparison]

5. Confirm the message, and then press "ENTER" key.

6. Select "INJECTION QUANTITY COMPARISON".

7. Perform the test in accordance with the message.

* (+) correction value: Injection quantity is less than the others.

You might also like