Fuel Injector: Service and Repair
FUEL INJECTOR AND FUEL TUBEFUEL INJECTOR AND FUEL TUBE:
CAUTION: Apply new engine oil when installing the parts that specified to do so in the figure.
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
1. Remove engine cover with power fool.
2. Release fuel pressure.
3. Remove fuel feed hose (with damper) from fuel sub-tube.
NOTE: There is no fuel return route.
CAUTION: While hoses are disconnected, plug them to prevent fuel from draining.
Do not separate damper and hose.
4. When separating fuel feed hose and centralized under-floor piping connection, disconnect quick connector with the following procedure.
a. Remove quick connector cap from quick connector connection on right side member.
b. Disconnect fuel feed hose from bracket hose clamp.
c. Remove the quick connectors as follows.
- Pick out retainer tab by hand and remove.
- If connector and centralized under-floor piping connection are stuck, push and pull several times until they start to move. Then disconnect them by pulling.
CAUTION: Keep parts away from heat source. Especially, be careful when welding is performed around them.
Do not expose parts to battery electrolyte or other acids.
Do not bend or twist connection between quick connector and fuel hose during installation/removal.
Do not remove retainer.
When replacing centralized under-floor piping, always replace retainer with a new one.
When replacing retainer, use same color retainer as was originally installed.
Retainer color: Green
To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
5. Remove intake manifold collector (upper) and (lower).
6. Remove a harness connector from fuel injector.
7. Loosen mounting bolts in the reverse order in the figure, and remove fuel tube and fuel injector assembly.
CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
8. Remove fuel injector from fuel tube with following procedure.
a. Open and remove clip.
b. Remove fuel injector from the fuel tube by pulling straight.
CAUTION: Be careful with remaining fuel that may go out from fuel tube.
Be careful not to damage injector nozzles during removal.
Do not bump or drop fuel injectors.
Do not disassemble fuel injectors.
9. Remove fuel sub-tube and fuel damper.
INSTALLATION
1. Install fuel damper and fuel sub-tube.
- When handling O-rings, be careful of the following:
CAUTION: Handle O-ring with bare hands. Never wear gloves.
Lubricate O-ring with new engine oil.
Do not clean O-ring with solvent
Make sure that O-ring and its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.
Insert O-ring straight into fuel tube. Do not decanter or twist it.
- Insert fuel damper and fuel sub-tube straight into fuel tube.
- Tighten mounting bolts evenly in turn.
- After tightening mounting bolts, make sure that there is no gap between flange and fuel tube.
2. Install O-rings to fuel injector paying attention to the items below.
CAUTION: Upper and lower O-ring are different. Be careful not to confuse them.
Fuel tube side : Black
Nozzle side : Green
- Handle O-ring with bare hands. Never wear gloves.
- Lubricate O-ring with new engine oil.
- Do not clean O-ring with solvent.
- Make sure that O-ring and its mating part are free of foreign material.
- When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.
- Insert O-ring straight into fuel tube. Do not decanter or twist it.
3. Install fuel injector to fuel tube with the following procedure.
a. Insert clip into clip mounting groove on fuel injector.
Insert clip so that lug "A" of fuel injector matches notch "A" of the clip.
CAUTION: Do not reuse clip. Replace it with a new one.
Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
- Insert it while matching it to the axial center.
- Insert fuel injector so that lug "B" of fuel tube matches notch "B" of the clip.
- Make sure that fuel tube flange is securely fixed in flange fixing groove on clip.
c. Make sure that installation is complete by checking that fuel injector does not rotate or come off.
4. Install fuel tube and fuel injector assembly to intake manifold.
CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts.
Tighten mounting bolts in two steps in numerical order shown in figure.
1st step:............9.3 - 10.8 Nm (0.95 - 1.1 kgf-cm, 0.7 - 0.8 ft. lbs.)
2nd step:............20.6 - 26.5 Nm (2.1 - 2.7 kgf-cm, 16 - 19 ft. lbs.)
6. Install intake manifold collector (upper) and (lower).
Install fuel sub-tube on rear end of intake manifold collector (lower).
7. Connect fuel feed hose (with damper).
- Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube.
- Insert fuel damper straight into fuel sub-tube.
- Tighten mounting bolts evenly in turn.
- After tightening mounting bolts, make sure that there is no gap between flange and fuel sub-tube.
8. Connect quick connector between fuel feed hose and centralized under-floor piping connection with the following procedure:
a. Check the connection for damage and foreign materials.
b. Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
c. After connecting the quick connector, use the following method to make sure it is full connected.
Visually confirm that the two retainer tabs are connected to the connector.
Pull the tube and the connector to make sure they are securely connected.
d. Install quick connector cap to quick connector connection.
Install quick connector cap with arrow on surface facing in direction of quick connector (fuel feed hose side).
CAUTION: If cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again.
e. Secure fuel feed hose to clamp.
9. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Check for fuel leakage with following procedure.
1. Turn ignition switch ON (do not start engine), and check connections for leakage by applying fuel pressure to fuel piping.
2. Start engine, and re-check connections for fuel leakage by increasing engine speed.