Replacing Injectors
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From: WAYNESBORO, SOUTH CENTRAL PA,
Replacing Injectors
Looking for help with torque specifications for the injector hold down bolts, the torque for the injector supply tube, exhaust rocker arm torque, common rail to supply tube torque. Thanking you in advance, Anthony C
Injector/Connector tube:
a. Install fuel injector holdown 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 and retaining nut. Do a preliminary tightening to 15 Nm (11 ft.
lbs.) torque.
d. Alternately tighten injector holdown bolts to 10 Nm (89 in. lbs.) torque.
e. Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 Nm (37 ft.
lbs.) torque
Rocker:
(9) Lubricate valve stem tips and install the crossheads
in their original locations.
(10) Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 20).
Install the bolts and torque them to 36 N·m (27 ft.
lbs.).
(11) Verify that the valve lash settings are maintained
Fuel Lines:
(18) Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand tighten fuel rail bolts.
(b) Hand tighten fuel drain line to pressure limiting
valve. Hand tighten banjo bolt at fuel filter
housing.
(c) Hand tighten fuel rail-to-cylinder head high
pressure fuel lines.
(d) Install fuel line brace bolts-to-intake manifold
finger tight.
(e) Hand tighten fuel pump to fuel rail line.
(f) Torque fuel line nuts at cylinder head to 30
Nm ( 22 ft. lbs.).
(g) Torque fuel line nuts at fuel rail to 30 Nm
(22 ft. lbs.)
(h) Using a back up wrench, torque fuel pump to
fuel rail line to 37 Nm (27 ft. lbs.). At injection
pump.
(i) Torque fuel pump to fuel rail line to 37 Nm
(27 ft. lbs.) at fuel rail.
(j) Torque fuel drain banjo bolt at pressure limiting
valve and front of fuel filter housing to 24 Nm
(18 ft. lbs.).
(k) Torque fuel line brace bolts to 24 N·m (18 ft.
lbs.).
(l) Torque rail bolts to 24 Nm (18 ft. lbs.).
(m) Connect fuel pressure sensor.
(19) Reposition number 6 fuel line shield and
torque to 43 N·m (32 ft. lbs.).
(20) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N·m (57 ft. lbs.).
(21) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N·m (18 ft. lbs.).
(22) Connect fuel return line at back of cylinder
head hand tight.
a. Install fuel injector holdown 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 and retaining nut. Do a preliminary tightening to 15 Nm (11 ft.
lbs.) torque.
d. Alternately tighten injector holdown bolts to 10 Nm (89 in. lbs.) torque.
e. Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 Nm (37 ft.
lbs.) torque
Rocker:
(9) Lubricate valve stem tips and install the crossheads
in their original locations.
(10) Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 20).
Install the bolts and torque them to 36 N·m (27 ft.
lbs.).
(11) Verify that the valve lash settings are maintained
Fuel Lines:
(18) Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand tighten fuel rail bolts.
(b) Hand tighten fuel drain line to pressure limiting
valve. Hand tighten banjo bolt at fuel filter
housing.
(c) Hand tighten fuel rail-to-cylinder head high
pressure fuel lines.
(d) Install fuel line brace bolts-to-intake manifold
finger tight.
(e) Hand tighten fuel pump to fuel rail line.
(f) Torque fuel line nuts at cylinder head to 30
Nm ( 22 ft. lbs.).
(g) Torque fuel line nuts at fuel rail to 30 Nm
(22 ft. lbs.)
(h) Using a back up wrench, torque fuel pump to
fuel rail line to 37 Nm (27 ft. lbs.). At injection
pump.
(i) Torque fuel pump to fuel rail line to 37 Nm
(27 ft. lbs.) at fuel rail.
(j) Torque fuel drain banjo bolt at pressure limiting
valve and front of fuel filter housing to 24 Nm
(18 ft. lbs.).
(k) Torque fuel line brace bolts to 24 N·m (18 ft.
lbs.).
(l) Torque rail bolts to 24 Nm (18 ft. lbs.).
(m) Connect fuel pressure sensor.
(19) Reposition number 6 fuel line shield and
torque to 43 N·m (32 ft. lbs.).
(20) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N·m (57 ft. lbs.).
(21) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N·m (18 ft. lbs.).
(22) Connect fuel return line at back of cylinder
head hand tight.
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