| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 298-5564 | T40 Torx Socket | 1 |
| C | 1U-5718 | Vacuum Pump | 1 |
| 169-7372 | Fluid Sampling Bottle | 1 | |
| 4C-4057 | Tube
|
1 | |
| D | 276-1216 | Injector Pipe Nut Tool | 1 |
| E | 247-5377 | Torque Wrench | 1 |
| NOTICE |
|---|
|
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training. Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. |
| NOTICE |
|---|
|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
|
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors. |
- If a replacement electronic unit injector is installed, the correct trim file for the injector must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Trim File" for more information. The code that is required to obtain the trim file for the injector is located at position (X).
Note: Record Code (X) before the electronic unit injector is installed.
- Use Tooling (D) in order to remove any fuel from the cylinder.
Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
- Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Show/hide table
Illustration 2 g01255701 - On installing an original electronic unit injector, install a new O-ring seal (15) and sealing washer (14) to electronic unit injector (11).
Ensure that the O-ring seal (15) and sealing washer (14) on a new electronic unit injector are not damaged and in place.
Note: Do not lubricate the O-ring seal.
- Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.
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Illustration 3 g01255699 The rocker shaft is not shown for clarity. - Position clamp (13) between the rocker arm and the valve springs. Align electronic unit injector (11) to the bore for the electronic unit injector in the cylinder head. Install the clamp to the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.
- Install a new torx screw (12) to clamp (13). Tighten the torx screw finger tight.
- Remove the cap from electronic unit injector (11). Install a new seal (8) to electronic unit injector (11) and to the valve mechanism cover base. Ensure that the flange on the seal is flush with the valve mechanism cover base.
- Remove the plugs from the new fuel injection line. Loosely install the fuel injection line. Refer to Disassembly and Assembly, "Fuel Injecton Lines - Install".
Note: Ensure that the ends of the fuel injection line are seated in the electronic unit injector and the fuel manifold. Tighten the nuts finger tight.
- Use Tooling (A) to tighten torx screw (12) to a torque of
27 N·m (20 lb ft) .Note: Tooling (A) must be used to ensure no damage to the rocker arms.
- Use Tooling (D) to tighten the fuel injection line to a torque of
30 N·m (22 lb ft) . Refer to Disassembly and Assembly, "Fuel Injecton Lines - Install".Show/hide table
Illustration 4 g01374098 Typical example Show/hide table
Illustration 5 g01355048 Early valve bridges
The electronic unit injector is not shown for clarity.Show/hide table
Illustration 6 g01806853 Later valve bridges
The electronic unit injector is not shown for clarity.Show/hide tableNOTICE Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.
- Install valve bridges (5) to the cylinder head. If valve bridges (5) are equipped with shrouds (16), ensure that the shrouds are located correctly.
Note: Ensure that used valve bridges are reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges.
- Ensure that the bottoms of the pushrods are seated in the cups of the valve lifters. Locate the balls of adjusters (2) into the cups of pushrods (4). Adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".
- Use a deep socket to install harness assembly (9) to electronic unit injector (11). Use Tooling (E) to tighten connections (10) to a torque of
2.4 N·m (21 lb in) .Show/hide table
Illustration 7 g01621539 - Tighten banjo bolt (6) for tube assembly (7). Tighten the banjo bolt to a torque of
21 N·m (15 lb ft) . - Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
- Turn the fuel supply to the ON position.
- Turn the battery disconnect switch to the ON position.
- Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.
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| Illustration 1 | g01341874 |
|
Typical calibration code | |
Alternative Installation Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 298-5564 | T40 Torx Socket | 1 |
| C | 1U-5718 | Vacuum Pump | 1 |
| 169-7372 | Fluid Sampling Bottle | 1 | |
| 4C-4057 | Tube
|
1 | |
| D | 276-1216 | Injector Pipe Nut Tool | 1 |
| E | 247-5377 | Torque Wrench | 1 |
Note: This is an optional procedure to install the electronic unit injectors. The method should ONLY be used when all electronic unit injectors are installed and when the engine is removed from the application.
| NOTICE |
|---|
|
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training. Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. |
| NOTICE |
|---|
|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
|
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors. |
- If a replacement electronic unit injector is installed, the correct trim file for the injector must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Trim File" for more information. The code that is required to obtain the trim file for the injector is located at Position (X).
Note: Record Code (X) before the electronic unit injector is installed.
- Use Tooling (C) to remove any fuel from the cylinder.
Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
- Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Show/hide table
Illustration 9 g01255701 - On installing an original electronic unit injector, install a new O-ring seal (15) and sealing washer (14) to electronic unit injector (11).
Ensure that the O-ring seal (15) and sealing washer (14) on a new electronic unit injector are not damaged and in place.
Note: Do not lubricate the O-ring seal.
- Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.
Show/hide table
Illustration 10 g01255699 - Install clamp (13) to electronic unit injector (11). Install the electronic unit injector assembly into the original location in the cylinder head.
Note: Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head. Install the electronic unit injector for number one cylinder.
- Install a new torx screw (12) to clamp (13). Tighten the torx screw finger tight.
- Remove the cap from electronic unit injector (11). Install a new seal (8) to electronic unit injector (11) and to the valve mechanism cover.
- Remove the plugs from the new fuel injection line. Loosely install the fuel injection line. Refer to Disassembly and Assembly, "Fuel Injecton Lines - Install".
Note: Ensure that the ends of the fuel injection line are seated in the electronic unit injector and the fuel manifold. Tighten the nuts finger tight.
- Use Tooling (A) to tighten torx screw (12) to a torque of
27 N·m (20 lb ft) . - Use Tooling (D) to tighten the fuel injection line to a torque of
30 N·m (22 lb ft) . Refer to Disassembly and Assembly, "Fuel Injecton Lines - Install". - Repeat Step 2 through Step 11 in order to install the remaining electronic unit injectors.
- Use a deep socket to install harness assemblies (9) to electronic unit injectors (11). Use Tooling (E) to tighten connections (10) to a torque of
2.4 N·m (21 lb in) .Show/hide table
Illustration 11 g01355048 Early valve bridges
The electronic unit injector is not shown for clarity.Show/hide table
Illustration 12 g01806853 Later valve bridges
The electronic unit injector is not shown for clarity.Show/hide tableNOTICE Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.
- Install valve bridges (5) to the cylinder head. If valve bridges (5) are equipped with shrouds (16), ensure that the shrouds are located correctly.
Note: Ensure that used valve bridges are reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges.
- Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft - Install".
Show/hide table
Illustration 13 g01621539 - Tighten banjo bolt (6) for tube assembly (7). Tighten the banjo bolt to a torque of
21 N·m (15 lb ft) . - Turn the fuel supply to the ON position.
- Turn the battery disconnect switch to the ON position.
- Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.
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| Illustration 8 | g01341874 |
|
Typical calibration code | |