Fuel Injector: Service and Repair

Injector:

REMOVAL
1. REMOVE SUSPENSION UPPER BRACE
2. REMOVE NO. 2 CYLINDER HEAD COVER
3. DISCONNECT PCV HOSE




4. DISCONNECT WIRE HARNESS CLAMPS
Disconnect the 3 wire harness clamps from the clamp brackets.




5. REMOVE INJECTORS
a. Disconnect the 4 injector connectors.
b. Remove the 2 bolts holding the delivery pipe to the cylinder head.
c. Disconnect the delivery pipe together with the 4 injectors from the cylinder head.

NOTE: Be careful not to drop the injectors when disconnecting the delivery pipe.

d. Remove the 2 spacers and 4 grommets.
e. Pull out the 4 injectors from the delivery pipe.
f. Remove the O-ring from each injector.

INSTALLATION




1. INSTALL INJECTORS AND DELIVERY PIPES
a. Apply a light coat of spindle oil or gasoline onto a new O-ring, and install it to each injector.




b. Install the 2 spacers and 4 new insulators to the cylinder head.




c. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches the O-ring.
d. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Then install the 4 injectors.
e. Position the injector connector upward.




f. Attach the delivery pipe together with the 4 injectors to the cylinder head.
g. Temporarily install the 2 bolts to hold the delivery pipe to the cylinder head.




h. Check that the injectors rotate smoothly.

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

i. Position the injector connector upward.




j. Tighten the 2 bolts holding the delivery pipe to the cylinder head.

Torque: 19 N.m (190 kgf.cm. 13 ft.lbf)

k. Connect the 4 injector connectors.




2. CONNECT WIRE HARNESS CLAMPS
Connect the 3 wire harness clamps to the clamp brackets.

3. CONNECT PCV HOSE
4. INSTALL NO. 2 CYLINDER HEAD COVER
5. INSTALL SUSPENSION UPPER BRACE

FUEL SYSTEM




a. Observe these precautions when disconnecting the fuel tube connector (quick type):
1. Disconnect the fuel pipe clamp from the connector.
2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.




3. Be sure to disconnect by hand.
4. When the connector and the pipe are stuck, pinch the retainer by hand, push and pull the connector to free the connection and pull it out. Do not use any tools at this time.
5. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.
6. Prevent the disconnected pipe and connector from being damaged and foreign objects mixing in objects by covering them with a vinyl bag.




b. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe.
2. Remove the retainer from the pipe by hand. Do not use any tools.
3. Check if there is any damage or foreign objects on the connected part of the pipe.




4. Match the axis of the connector with the axis of the pipe, and push in the connector until the retainer makes a "click" sound. In case that the connection is tight, apply a little amount of new engine oil onto the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.




6. Install the fuel pipe clamp to the connector.
7. Check if there is any fuel leak.