Fuel Injector: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
5. DISCONNECT FUEL TUBE SUB-ASSEMBLY
a. Remove the No. 1 fuel pipe clamp.
NOTE: Check for foreign matter on the pipe and around the connector before disconnecting the quick connector. Clean the connector if necessary.
b. If the connector and pipe are stuck, pinch the connector, and push and pull the pipe to disconnect them.
NOTE:
- Do not use any tools in this procedure.
- Check for foreign matter on the sealing surface of the disconnected pipe. Clean it if necessary.
c. Separate the fuel tube from the fuel hose clamp.
6. DISCONNECT NO. 2 VENTILATION HOSE
a. Disconnect the No. 2 ventilation hose from the ventilation valve.
7. REMOVE FUEL DELIVERY PIPE WITH INJECTOR
a. Remove the 2 wire harness clamps.
b. Disconnect the 4 fuel injector connectors.
c. Remove the 2 bolts, then remove the fuel delivery pipe together with the 4 fuel injectors.
NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
d. Remove the 2 delivery pipe spacers from the cylinder head.
e. Remove the 4 insulators from the cylinder head.
8. REMOVE FUEL INJECTOR ASSEMBLY
a. Pull out the 4 injectors from the delivery pipe.
b. Remove the 4 O-rings from the injectors.
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
a. Apply a light coat of gasoline or spindle oil to new Orings, then install one onto each fuel injector.
b. Apply a light coat of gasoline or spindle oil to the part of 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 Oring again, then install the right and left fuel injectors onto the fuel delivery pipe.
NOTE: Make sure that the O-ring is not cracked or jammed before installing the injector.
d. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring.
2. INSTALL FUEL DELIVERY PIPE WITH INJECTOR
a. Install 4 new insulators into the cylinder head.
b. Install the 2 delivery pipe spacers onto the cylinder head.
c. Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 2 bolts.
NOTE: Be careful not to 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 smoothly, replace the O-ring.
e. Tighten the 2 bolts to the specified torque.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
f. Connect the 4 fuel injector connectors.
g. Install the 2 wire harness clamps.
3. INSTALL NO. 2 VENTILATION HOSE
a. Connect the ventilation hose to the ventilation valve.
NOTE: Make sure that the paint mark and hose clamp are positioned as shown in the illustration after connecting the hose.
4. CONNECT FUEL TUBE SUB-ASSEMBLY
a. Install the fuel tube to the fuel hose clamp.
b. Push the fuel tube connector until it makes a "click" sound.
c. Install the No. 1 fuel pipe clamp.
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
7. CHECK FOR FUEL LEAKS
8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY