Fuel Injector: Service and Repair

REMOVAL

1. REMOVE ENGINE UNDER COVER
2. REMOVE THROTTLE BODY
3. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
(a) Remove the bolt.
(b) Pull out the dipstick guide together with the dipstick.

HINT: At the time of installation, please refer to the following items. Apply clean transmission oil to the O-ring, and push in the dip stick guide.

(c) Remove the O-ring from the dipstick guide.

HINT: At the time of installation, please refer to the following items. Use a new O-ring.

4. REMOVE OIL DIPSTICK AND GUIDE FOR ENGINE

(a) Disconnect the fuel return hose from the clamp of the dipstick guide.
(b) Remove the bolt.
(c) Pull out the dipstick guide together with the dipstick.

HINT: At the time of installation, please refer to the following items. Apply clean engine oil to the O-ring, and push in the dipstick guide.

(d) Remove the O-ring from the dipstick guide.

HINT: At the time of installation, please refer to the following items. Use a new O-ring.

5. REMOVE AIR INTAKE CHAMBER STAY
Remove the bolt, nut and chamber stay.

Torque: 19.5 N.m (195 kgf.cm, 14 ft.lbf)

6. DISCONNECT CONTROL CABLE BRACKET FROM AIR INTAKE CHAMBER
Remove the 2 bolts, and disconnect the cable bracket from the air intake chamber.

Torque: 19.5 N.m (195 kgf.cm, 14 ft.lbf)

7. DISCONNECT CONNECTORS AND HOSES

(a) Disconnect these connectors:
(1) IAC valve connector
(2) Turbo pressure sensor connector
(3) [1][2]VSV connector for fuel pressure control
(4) [1][2]VSV connector for EGR

(b) Remove the bolt, and disconnect the engine wire protector from the body.
(c) Disconnect these hoses:

(1) Air hose from AC valve
Disconnect the AC valve pipe from the clamp on the cylinder head cover, and disconnect the air hose from the IAC valve.
(2) Air hose (from air intake chamber) from vacuum pipe on AC valve pipe
(3) Air hose for EGR from valve pipe

(4) PCV hose from PCV valve
(5) Vacuum sensing hose from fuel pressure regulator

(6) Water bypass hose (from IAC valve) from No.4 water bypass pipe
(7) EVAP hose (from air intake chamber) from vacuum pipe on manifold stay
(8) EVAP hose (from vacuum pipe on No.4 water bypass pipe) from No.2 vacuum pipe
(9) EVAP hose (from charcoal canister) from No.2 vacuum pipe
(10) PS air hose from air intake chamber
(11) Brake booster vacuum hose from union on air intake chamber

8. DISCONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR
(a) Disconnect the connector from the No.2 vacuum pipe.
(b) Disconnect the sensor connector from the wiring connector.
9. REMOVE EGR PIPE
(a) Remove the union bolt holding the EGR pipe to the EGR valve.

Torque: 65 N.m (650 kgf.cm, 48 ft.lbf)

(b) Remove the 2 bolts, EGR pipe and gasket.

HINT: At the time of installation, please refer to the following items. Use a new gasket.

Torque: 28 N.m (280 kgf.cm, 21 ft.lbf)

10. REMOVE NO.4 WATER BYPASS PIPE
Remove the 2 bolts and water bypass pipe.
11. REMOVE MANIFOLD STAY
Remove the 2 bolts and manifold stay.

Torque: 40 N.m (400 kgf.cm, 30 ft.lbf)

12. REMOVE AIR INTAKE CHAMBER ASSEMBLY

(a) Remove the bolt, and disconnect the ground cable from the intake manifold.
(b) Remove the 2 bolts holding the engine wire protector to the intake manifold.
(c) Disconnect the 2 clamps of the engine wire protector from the brackets.

(d) Remove the 5 bolts, 2 nuts and engine wire bracket, and disconnect the air intake chamber assembly from the intake manifold.

HINT: At the time of installation, please refer to the following items. Uniformly tighten the bolts and nuts in several passes.

Torque: 28 N.m (280 kgf.cm, 21 ft.lbf)

(e) Disconnect the water bypass hose from the IAC valve.
(f) Remove the gasket.

HINT: At the time of installation, please refer to the following items. Use a new gasket.

13. DISCONNECT WIRE CLAMPS AND CONNECTORS
Disconnect these connectors and clamps:
(1) 6 injectors connectors

HINT: At the time of installation, please refer to the following items. The No.1, No.3 and No.5 injector connectors are dark gray, and the No.2, No.4 and No.6 injector connectors are gray.

(2) 2 camshaft position sensor connectors
(3) 3 engine wire clamps from injector holders

14. DISCONNECT FUEL INLET PIPE FROM DELIVERY PIPE
Remove the union bolt and 2 gaskets, and disconnect the inlet pipe from the delivery pipe.

HINT: At the time of installation, please refer to the following items.
Use 2 new gaskets.

Torque: 42 N.m (420 kgf.cm, 31 ft.lbf)

CAUTION:
- Put a shop towel under the delivery pipe.
- Slowly loosen the union bolt.

15. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR
16. REMOVE DELIVERY PIPE AND INJECTORS

(a) Remove the 6 bolts and 3 injector holders.

Torque: 8.0 N.m (80 kgf.cm, 71 in..lbf)

(b) Remove the 6 insulators from the injectors.

HINT: At the time of installation, please refer to the following items.
Use 6 new insulators.

(d) Remove the 2 spacers from the intake manifold.

(e) Remove the 6 insulators from the delivery pipe.

HINT: At the time of installation, please refer to the following items. Use 6 new insulators.

REPLACEMENT

1. REMOVE INJECTORS

(a) Apply gasoline between the delivery pipe and injectors.

(b) Using SST lift up the 6 injectors. SST 09268-74010
(c) Remove the insulator and 2 O-rings from each injector.
2. REINSTALL INJECTORS
(a) Apply a light coat of gasoline to 2 new O-rings.

(b) Install the 2 O-rings and new insulator to each injector.

(c) Push in the 6 injectors so that the injector connectors are positioned as shown in the illustration.

INSTALLATION
Installation is in the reverse order of removal.