Fuel Injector: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE NO. 2 CYLINDER HEAD COVER
a. Remove the 2 clips and 2 nuts, then remove the No. 2 cylinder head cover.
4. REMOVE 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 (A).
b. Remove the 3 wire harness clamps from the clamp brackets (B).
c. Remove the fuel pipe clamp No. 1 (C).
d. Disconnect the fuel tube (D).
e. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe (E).
NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if 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.
- Only disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes.
- Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
f. Remove the 3 bolts, then remove the fuel delivery pipe together with the fuel injector (F).
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 (G).
h. Remove the 4 insulators from the cylinder head (H).
6. REMOVE FUEL INJECTOR ASSEMBLY
a. Pull the 4 fuel injectors out of the fuel delivery pipe.
INSTALLATION
1. 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.
2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Install 4 new insulators into the cylinder head (A).
b. Install the 2 delivery pipe No. 1 spacers onto the cylinder head (B).
NOTE: Make sure that the delivery pipe No. 1 spacers are installed in the correct direction.
c. Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 3 bolts (C).
NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe.
d. Check that the fuel injector rotates smoothly (D). If the fuel injector does not rotate, replace the O-ring.
e. Tighten the 3 bolts to the specified torque (E).
Torque:
Bolt A 19 N.m (194 kgf.cm, 14 ft.lbf)
Bolt B 9.0 N.m (92 kgf.cm, 80 in.lbf)
f. Connect the fuel tube (F).
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 (G).
h. Install the 3 wire harness clamps (H).
i. Connect the 4 fuel injector connectors (I).
3. 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.
4. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
5. INSPECT FOR FUEL LEAK
6. INSTALL NO. 2 CYLINDER HEAD COVER
a. Install the No. 2 cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N.m (70 kgf.cm, 62 in.lbf)