Fuel Injector: Service and Repair
REPLACEMENT1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 2 clips and 2 nuts, then remove the cylinder head cover No. 2.
4. DISCONNECT VENTILATION HOSE
a. Disconnect the ventilation hose from the cylinder head cover.
5. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Disconnect the 4 fuel injector connectors.
b. Remove the 3 wire harness clamps from the clamp brackets.
c. Remove the fuel pipe clamp No. 1.
d. Disconnect the fuel tube.
e. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
f. Remove the 3 bolts, then remove the fuel delivery pipe together with the fuel injector.
NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
g. Remove the 2 delivery pipe spacers from the cylinder head.
h. Remove the 4 insulators from the cylinder head.
6. REMOVE FUEL INJECTOR ASSEMBLY
a. Pull the 4 fuel injectors out of the fuel delivery pipe.
7. INSTALL FUEL INJECTOR ASSEMBLY
a. Apply a light coat of gasoline or spindle oil to a new O-ring, then install it onto each fuel injector.
b. Apply a light coat of gasoline or spindle oil to the fuel delivery pipe which comes into contact with the O-ring of the fuel injector.
c. Apply a light coat of gasoline or spindle oil to the O-ring again, then install the fuel injector right and left onto the fuel delivery pipe.
NOTE: Make sure that the O-ring is not cracked or jammed when installing.
d. Check that the fuel injector rotates smoothly.
If the fuel injector does not rotate, replace the O-ring.
8. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Install 4 new insulators into the cylinder head.
b. Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
NOTE: Make sure that the delivery pipe No. 1 spacer is in the correct direction when installing.
c. Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 3 bolts.
NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe.
d. Check that the fuel injector rotates smoothly.
If the fuel injector does not rotate, replace the O-ring.
e. Tighten the 3 bolts to the specified torque.
Torque:
19 N.m (194 kgf.cm, 14 ft.lbf) for bolt A
9.0 N.m (92 kgf.cm, 80 in.lbf) for bolt B
f. Connect the fuel tube.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tube to the pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tube, check that the fuel tube is securely connected by pulling the fuel tube connector.
g. Install the fuel pipe clamp No. 1.
h. Install the 3 wire harness clamps.
i. Connect the 4 fuel injector connectors.
9. CONNECT VENTILATION HOSE
a. Connect the ventilation hose to the cylinder head cover.
NOTE: Make sure that the hose clamp is at the correct angle when installing.
10. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
11. CHECK FOR FUEL LEAKAGE
12. INSTALL CYLINDER HEAD COVER NO.2
a. Install the cylinder head cover No. 2 with the 2 nuts and 2 clips.
Torque: 7.0 N.m (70 kgf.cm, 62 in.lbf)