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Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air. 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 (0.06 inchess) 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. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring. Install injector into cylinder head with male (highpressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector.
Tightening Sequence:Install fuel injector holdown clamp (mounting flange) bolts. 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. After tightening, relieve bolt torque, but leave both bolts threaded in place. Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 Nm (11 ft. lbs.) torque. Alternately tighten injector holdown bolts to 10 Nm (89 in. lbs.) torque. Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 Nm (37 ft. lbs.) torque.Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 1.25 Nm (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur. Install exhaust rocker arm assembly. Set exhaust valve lash. Install high pressure fuel line. Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting.