Fuel Injector: Service and Repair
REMOVAL1. PREVENT GASOLINE FROM SPILLING OUT
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN ENGINE COOLANT
4. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
5. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
6. REMOVE COWL TOP VENTILATOR LOUVER RH
7. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSEMBLY
8. REMOVE COWL TOP PANEL OUTER
9. REMOVE V-BANK COVER SUB-ASSEMBLY
a. Disengage the 3 clips and remove the V-bank cover.
NOTE: Be sure to disengage the clips in the order from A to B.
10. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
a. Disconnect the 3 vacuum hoses.
b. Disconnect the ventilation hose No.1.
c. Disconnect the air flow meter connector.
d. Separate the fuel vapor feed hose No.1.
e. Loosen the hose clamp bolt.
f. Remove the 3 clamps and air cleaner cap with air cleaner hose.
11. REMOVE INTAKE AIR SURGE TANK
a. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly.
b. Disconnect the vapor feed hose.
c. Disconnect the throttle with motor body assembly connector and clamp.
d. Disconnect the ventilation hose No.2.
e. Disconnect the union to check valve hose.
f. Remove the bolt and vacuum hose clamp.
g. Disconnect the connector.
h. Using a 5 mm socket hexagon wrench, remove the 4 bolts.
i. Remove the 2 nuts, 2 bolts and intake air surge tank.
j. Remove the gasket from the intake air surge tank.
12. DISCONNECT FUEL TUBE SUB-ASSEMBLY
a. Remove the fuel pipe clamp No.2.
b. Pinch the tube connector and then pull out the fuel pipe.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
- It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Do not use any tools in this operation.
- Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
- When the pipe and the connector are stuck, push and pull the connector to release and pull the connector out carefully.
13. REMOVE FUEL INJECTOR ASSEMBLY
a. Disconnect the 6 fuel injector connectors.
b. Remove the 5 bolts and fuel delivery pipe together with the 6 fuel injectors.
NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
c. Remove the 6 insulators from the intake manifold.
d. Pull out the fuel injector from the fuel delivery pipe.
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
a. Apply a light coat of spindle oil or gasoline to new O-rings, and install one to each injector.
b. Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts the O-ring.
c. Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
d. Position the fuel injector connector outward.
NOTE:
- Be careful not to twist the O-ring.
- After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
e. Install 6 new insulators to the intake manifold.
f. Place the fuel delivery pipe and the 6 fuel injectors together to the intake manifold.
NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
g. Temporarily install the 6 bolts which are used to hold the fuel delivery pipe to the intake manifold.
NOTE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
h. Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
i. Connect the 6 fuel injector connectors.
2. CONNECT FUEL TUBE SUB-ASSEMBLY
a. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
NOTE:
- Check that there is no damage or foreign objects on the connected part of the fuel pipe.
- After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
b. Install the fuel pipe clamp No.2.
3. INSTALL INTAKE AIR SURGE TANK
a. Install a new gasket to the intake air surge tank.
b. Using a 5 mm hexagon socket wrench, install the 4 bolts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
c. Install the intake air surge tank with the 2 nuts and 2 bolts.
Torque:
Nut:
16 N.m (163 kgf.cm, 12 ft.lbf)
Bolt:
21 N.m (214 kgf.cm, 15 ft.lbf)
d. Connect the connector.
e. Install the vacuum hose clamp with the bolt.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
f. Connect the union to check valve hose.
g. Connect the ventilation hose No.2.
h. Install the clamp and connect the throttle with motor body assembly connector.
i. Connect the vapor feed hose.
j. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
4. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
a. Install the 3 clamps and air cleaner cap with air cleaner hose.
b. Tighten the hose clamp bolt.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
c. Connect the air flow meter connector.
d. Connect the ventilation hose No.1.
e. Connect the 3 vacuum hoses.
f. Connect the fuel vapor feed hose No.1.
5. INSTALL COWL TOP PANEL OUTER
6. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY
7. INSTALL COWL TOP VENTILATOR LOUVER RH
8. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
9. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
10. ADD ENGINE COOLANT
11. CONNECT BATTERY NEGATIVE TERMINAL
12. INSPECT FOR ENGINE COOLANT LEAK
13. INSPECT FOR FUEL LEAK
14. INSTALL V-BANK COVER SUB-ASSEMBLY
a. Engage the 3 clips and install the V-bank cover.
NOTE: Be sure to engage the clips in the order from A to B.
15. PERFORM INITIALIZATION
a. Some systems need initialization when disconnecting the battery terminal.