Fuel Injector: Service and Repair

COMPONENTS FOR REMOVAL AND INSTALLATION

INJECTORS REMOVAL

1. REMOVE AIR CLEANER HOSE AND CAP
2. DISCONNECT THROTTLE BODY AND AIR INTAKE CHAMBER COVER ASSEMBLY





(a) Disconnect these the hoses and connectors:
(1) 2 PCV hoses from cylinder head cover
(2) Vacuum sensing hose from fuel pressure regulator





(3) EGR hose from EGR valve
(4) Vacuum hose from EGR valve
(5) VSV (for EGR) connector





(b) Using a 6 mm hexagon wrench, remove the 3 bolts and 2 nuts, and disconnect the throttle body and chamber cover assembly from the intake manifold.
(c) Remove the gasket.
3. DISCONNECT INJECTOR CONNECTORS





4. DISCONNECT FUEL INLET HOSE FROM DELIVERY PIPE
Remove the union bolt and 2 gasket, and disconnect the inlet hose from the delivery pipe.

HINT:
- Put a suitable container or shop towel under the delivery pipe.
- Slowly loosen the union bolt.

5. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR
6. REMOVE DELIVERY PIPE AND INJECTORS





(a) Remove the 2 bolts and delivery pipe together with the 4 injectors.

NOTICE: Be careful not to drop the injectors when removing the delivery pipe.

(b) Remove the 4 insulators and 2 spacers from the intake manifold.
(c) Pull out the 4 injectors from the delivery pipe.
(d) Remove the O-ring and grommet from each injector.

INJECTORS INSTALLATION

1. INSTALL INJECTORS AND DELIVERY PIPE





(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new O-ring and install it to the injector.
(c) While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors.





(d) Position the injector connector upward.





(e) Place 4 new insulators and the 2 spacers in position on the intake manifold.
(f) Place the 4 injectors and delivery pipe assembly in position on the intake manifold.
(g) Temporarily install the 2 bolts holding the delivery pipe to the intake manifold.
(h) Check that the injectors rotate smoothly.

HINT: If the injectors do not rotate smoothly, the probable cause is incorrect installation of the O-rings. Replace the O-rings.





(i) Position the injector connector upward.
(j) Tighten the 2 bolts holding the delivery pipe to the intake manifold.

Torque: 15 N.m (150 kgf.cm, 11 ft.lbf)

2. CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR





3. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
Connect the inlet hose with 2 new gaskets and the union bolt.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

4. CONNECT INJECTOR CONNECTORS

HINT: The No.1 and No.3 injector connectors are gray, and the No.2 and No.4 injector connectors are dark gray.

5. CONNECT THROTTLE BODY AND AIR INTAKE CHAMBER COVER ASSEMBLY

(a) Place a new gasket on the intake manifold.





(b) Using a 6 mm hexagon wrench. connect the throttle body and chamber cover assembly with the 3 bolts and 2 nuts in the sequence shown.

Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)

(c) Connect these hoses and connectors:





(1) 2 PCV hoses to cylinder head cover
(2) Vacuum sensing hose to fuel pressure regulator





(3) EGR hose to EGR valve
(4) Vacuum hose to EGR valve
(5) VSV (for EGR) connector
6. INSTALL AIR CLEANER HOSE AND CAP