Fuel Injector: Service and Repair

Injector:

REMOVAL
1. REMOVE SUSPENSION UPPER BRACE
2. REMOVE AIR CLEANER HOSE
3. REMOVE AIR INTAKE CHAMBER ASSEMBLY
4. DISCONNECT INJECTOR CONNECTORS




5. REMOVE AIR ASSIST HOSES AND PIPE
a. Disconnect the air assist pipe from the bracket on the No.1 fuel pipe.
b. Remove the air assist hoses from the intake manifold.




6. DISCONNECT FUEL INLET PIPE




7. REMOVE DELIVERY PIPES AND INJECTORS

NOTE:
- Be careful not to drop the injectors when removing the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.

a. Remove the 5 bolts and delivery pipes together with the 6 injectors and fuel pipe.
b. Remove the 4 spacers from the intake manifold.
c. Pull out the 6 injectors from the delivery pipes.
d. Remove the 2 O-rings and 2 grommets from each injector.

INSTALLATION




1. INSTALL INJECTORS AND DELIVERY PIPES
a. Install new insulator and grommet to each injector.
b. Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector.




c. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches an O-ring of the injector.
d. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors.
e. Position the injector connector outward.




f. Place the 4 spacers in position on the intake manifold.




g. Apply a light coat of spindle oil or gasoline on the place where a intake manifold touches an O-ring of the injector.
h. Place the delivery pipes and fuel pipe together with the 6 injectors in position on the intake manifold.
i. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold.
j. Temporarily install the bolt holding the fuel pipe to the intake manifold.




k. Check that the injectors rotate smoothly.

HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

l. Position the injector connector outward.




m. Tighten the 4 bolts holding the delivery pipes to the intake manifold.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

n. Tighten the bolt holding the fuel pipe to the intake manifold.

Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf)




2. CONNECT FUEL INLET PIPE
a. Align the alignment marks (white paint) on the fuel inlet pipe.




b. Connect the fuel inlet pipe (fuel tube connector) to the fuel filter.




3. INSTALL AIR ASSIST HOSES AND PIPE
a. Connect the air assist hoses to the intake manifold.
b. Install the air assist pipe to the bracket on the No. 1 fuel pipe.

4. CONNECT INJECTOR CONNECTORS
5. INSTALL AIR INTAKE CHAMBER ASSEMBLY
6. INSTALL AIR CLEANER HOSE
7. INSTALL SUSPENSION UPPER BRACE

Install the suspension upper brace with the 4 nuts.

Torque: 80 N.m (820 kgf.cm, 59 ft.lbf)

8. CHECK FOR FUEL LEAKS

FUEL SYSTEM




a. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring.
2. When placing a new O-ring on the injector, take care not to damage it in any way.
3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil.




b. Install the injector to the delivery pipe and intake manifold, as shown in the illustration.

Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector.