Fuel Injector: Service and Repair
REPLACEMENT1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
4. DRAIN ENGINE COOLANT
5. REMOVE INTAKE AIR CONNECTOR
6. REMOVE THROTTLE W/MOTOR BODY ASSEMBLY
7. DISCONNECT FUEL HOSE
a. Pull the checker of the fuel hose upward.
b. Pinch the detaching switch of the fuel hose connector and pull out the fuel hose.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel hose.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
8. DISCONNECT FUEL HOSE NO.2
a. Pull the checker of the fuel hose upward.
b. Pinch the detaching switch of the fuel hose connector and pull out the fuel hose.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel hose.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
9. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
10. REMOVE FUEL DELIVERY PIPE W/INJECTOR
a. Disconnect the 4 injector connectors.
b. Disconnect the VSV connector.
c. Disconnect the engine wire harness clamp.
d. Disconnect the compressor magnetic clutch connector.
(w/ AIR CONDITIONING)
e. Disconnect the wire harness clamp.
f. Remove the bolt, then remove the harness clamp bracket.
g. Remove the 2 bolts, then remove the fuel delivery pipe together with the fuel injectors.
NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
h. Remove the 2 delivery pipe No.1 spacers.
i. Remove the 4 injector vibration insulators.
j. Using a screwdriver, remove the 4 spacers.
11. REMOVE FUEL INJECTOR ASSEMBLY
a. Pull the 4 fuel injectors out of the fuel delivery pipe.
12. INSTALL FUEL INJECTOR ASSEMBLY
a. Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each fuel injector.
b. Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and 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 into the fuel delivery pipe by turning it right and left.
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.
13. INSTALL FUEL DELIVERY PIPE W/INJECTOR
a. Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each spacer.
b. Install the 4 spacers onto the cylinder head.
c. Install 4 new injector vibration insulators onto the cylinder head.
d. Install the 2 delivery pipe No.1 spacers onto the cylinder head.
e. Install the fuel delivery pipe together with the 4 fuel injectors, then provisionally tighten the fuel delivery pipe with the 2 bolts.
NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe.
f. Check that the fuel injector rotates smoothly.
If the fuel injector does not rotate, replace the O-ring.
g. Retighten the 2 bolts to the specified torque.
Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
h. Install the harness clamp bracket with the bolt.
Torque: 8.2 N.m (84 kgf.cm, 73 in.lbf)
i. Connect the wire harness clamp.
j. Connect the compressor magnetic clutch connector. (w/ AIR CONDITIONING)
k. Connect the engine wire harness clamp.
l. Connect the VSV connector.
m. Connect the 4 injector connectors.
14. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
15. CONNECT FUEL HOSE
a. Align the fuel hose connector with the pipe stem, and insert the fuel hose until the retainer makes a click sound.
b. Push down the checker of the fuel hose.
NOTE:
- Check that there are no scratches or foreign objects around the disconnected parts of the fuel hose connector and pipe before performing this work.
- After connecting the fuel hose, check that the fuel hose is securely connected by pulling the fuel hose connector and pipe.
c. Push the fuel hose down until the checker of the fuel hose makes a "click" sound.
16. CONNECT FUEL HOSE NO.2
a. Align the fuel hose connector with the pipe stem, and insert the fuel hose until the retainer makes a "click" sound.
b. Push down the checker of the fuel hose.
NOTE:
- Check that there are no scratches or foreign objects around the disconnected parts of the fuel hose connector and pipe before performing this work.
- After connecting the fuel hose, check that the fuel hose is securely connected by pulling the fuel hose connector and pipe.
c. Push the fuel hose down until the checker of the fuel hose makes a "click" sound.
17. INSTALL THROTTLE W/MOTOR BODY ASSEMBLY
18. INSTALL INTAKE AIR CONNECTOR
19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)
20. ADD ENGINE COOLANT
21. CHECK FOR ENGINE COOLANT LEAKAGE
22. CHECK FOR FUEL LEAKAGE
23. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1