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 Oring 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 Oring.
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 Oring.
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)