Installation Procedure
- Record the Injector Flow Identifier Information from the new injector (s).
Install the NEW high pressure diesel fuel injector (1) to the cylinder head.
- NOTE:
Note the mounting position of the injector bracket.
Multiport Fuel Injector Bracket (2) - Install
- Fuel Injector Bolt (1) - Install, but do NOT tighten
Fuel Injection Fuel Return Pipe (1) - Install
Engage the fuel return hose connector (4), as needed.
Install the fuel injector wiring harness and connect the fuel injector wiring harness retainers (2), as needed.
- Connect the high pressure diesel fuel injector electrical connectors (1), as needed.
Install NEW high pressure diesel fuel feed to injector pipe (s) (2), as needed.
- Hand tighten the high pressure diesel fuel feed to injector pipe fittings (1), as needed.
- Tighten the high pressure diesel fuel feed to injector pipe fittings (1), as needed. Fastener Specifications
- NOTE:
Tighten the fuel injector bolt only after installing the high pressure diesel fuel feed pipes.
CAUTION:Refer to Fastener Caution .
Using the EN-45059-A Angle Meter tighten the fuel injector bolt (1). Fastener Specifications
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
NOTE:Ensure the camshaft housing cover insulator is properly seated.
Camshaft Housing Cover Insulator (1) - Install
Exhaust Gas Recirculation Pipe Bracket (5) - Install
- Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Reposition harness, hoses, and connect electrical connectors as needed.
Charge Air Cooler Bracket (2) - Install
- Charge Air Cooler Bolt (1) - Install and tighten [5x] - Fastener Specifications
Engine Coolant Air Bleed Hose Clip (1) - Install
Oil Filler Tube Support Stud (1) - Install - Fastener Specifications
Engine Wiring Harness Bracket - (3) Install
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Bracket Bolt (1) - Install and tighten - Fastener Specifications
Intake Manifold Resonator (2) - Install
- Engage the retaining spring (1).
Turbocharger Heat Shield (1) - Install
Turbocharger Heat Shield Nut (2) - Install and tighten - Fastener Specifications
- Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Install the upper intake manifold bracket (2) with nitrogen oxides sensor attached.
- Upper Intake Manifold Brace Nut (1) - Install and tighten [3x] - Fastener Specifications
Charge Air Cooler (1) - Install
Charge Air Cooler Bolt (1) - Install [4x] - Fastener Specifications
Charge Air Cooler Inlet Air Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Charge Air Cooler Outlet Air Hose (2) - Install
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Wiring Harness Retainer (4) @Charge Air Cooler - Install
Engine Wiring Harness (4) - Reposition
- Wiring Harness Retainer (2) @Charge Air Cooler - Install [3x]
- Electrical Connector (3) @Charge Air Cooler - Connect [2x]
- Electrical Connector (1) @Nitrogen Oxides Sensor - Connect
Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) - Install NEW
- Exhaust Gas Recirculation Pipe Seal (2) - Install NEW
- Exhaust Gas Recirculation Pipe (1) - Install
- NOTE:
Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).
Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications .
Exhaust Gas Recirculation Outlet Pipe Bolt (2) - Install and tighten - Fastener Specifications
- Install the turbocharger coolant return hose clip (1).
Install and tighten the turbocharger coolant feed and return pipe bolt (3). Fastener Specifications
- NOTE:
Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Exhaust Gas Recirculation Cooler Bolt (1) - Install and tighten [2x] - Fastener Specifications .
Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Install the rear engine wiring harness channel (2).
- Install and tighten the 3 engine wiring harness bracket nuts (1). Fastener Specifications
Air Cleaner Outlet Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
Air Cleaner Outlet Front Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
Oil Filler Cap - Remove
- Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
- Plenum Front Panel Outer Reinforcement - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
- Prime the fuel system and inspect for leaks. Fuel System Priming
- Start the engine and check for exhaust leaks.
- Perform the following steps:
- High Pressure Fuel Variable Reset High Pressure Fuel Variable Reset
- Fuel Injector Flow Rate Programming Fuel Injector Flow Rate Programming
Do NOT tighten the fuel injector bolt until after the high pressure diesel fuel feed pipes are installed.
Refer to Component Fastener Tightening Caution .
Refer to Fastener Caution .