Fuel Injector: Service and Repair

Fuel Injector:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

CAUTION:
- The DISCHARGE FUEL SYSTEM PRESSURE procedures must be performed before disconnecting any part of the fuel system.
- After performing the DISCHARGE FUEL SYSTEM PRESSURE procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray.

a. Remove the integration relay (unit C: C/OPN relay) from the engine room junction block.
b. Start the engine. After the engine has stopped, turn the power switch off.

HINT: DTC P0171 (system too lean) may be set.

c. Check that the engine does not start.
d. Remove the fuel tank cap, and let the air out of the fuel tank.
e. Disconnect the cable from the negative (-) battery terminal.

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

f. Install the integration relay (unit C: C/OPN relay) to the engine room junction block.

2. REMOVE WINDSHIELD WIPER MOTOR AND LINK
a. Remove the windshield wiper motor and link.

3. REMOVE FRONT OUTER COWL TOP PANEL SUBASSEMBLY

a. Remove the 2 bolts and disconnect the No. 2 engine room relay block.
b. Remove the 4 wire harness clamps.

c. Remove the 7 bolts and panel.

4. REMOVE AIR CLEANER ASSEMBLY
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

a. Disconnect the brake fluid level switch connector.
b. Remove the 2 bolts.
c. Disconnect the claw fitting, then remove the brake master cylinder reservoir.

6. REMOVE RESERVOIR BRACKET

a. Remove the No. 2 fuel vapor feed hose from the hose clamp.
b. Remove the connector clamp.
c. Remove the wire harness clamp.
d. Remove the 3 bolts and reservoir bracket.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

a. Remove the 2 wire harness clamps.
b. Disconnect the 4 fuel injector connectors.
c. Disconnect the 4 ignition coil connectors.
d. Remove the 3 bolts, then remove the engine wire and brake master cylinder reservoir cover.

e. Remove the 4 bolts and 4 ignition coils.

f. Disconnect the ventilation hose from the ventilation valve.
g. Disconnect the No. 2 ventilation hose from the cylinder head cover.

h. Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover.

8. REMOVE FUEL DELIVERY PIPE
a. Disconnect the fuel tube from the fuel delivery pipe.

1. Remove the No. 1 fuel pipe clamp.

2. Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the fuel tube from the fuel delivery pipe.

NOTE:
- Remove dirt or foreign objects on the fuel tube connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them, as the fuel tube connector has the O-rings that seal the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull them to release them.

b. Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors.

NOTE: Do not drop the fuel injectors when removing the fuel delivery pipe.

c. Remove the 2 No. 1 delivery pipe spacers from the cylinder head.
d. Remove the 4 insulators from the cylinder head.

9. REMOVE FUEL INJECTOR ASSEMBLY

a. Pull out the 4 fuel injectors from the fuel delivery pipe.

INSTALLATION

1. INSTALL FUEL INJECTOR ASSEMBLY

a. Apply a light coat of spindle oil or gasoline to a new O-ring, then install it to each fuel injector.

b. Apply a light coat of spindle oil or gasoline to the surface of the fuel delivery pipe which contacts the O-ring of the fuel injector.
c. Apply a light coat of spindle oil or gasoline to the Oring again, and install the fuel injector by turning it right and left while pushing it onto the fuel delivery pipe.

NOTE: Be careful that the O-ring is not cracked or jammed when installing it.

d. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the Oring.

2. INSTALL FUEL DELIVERY PIPE

a. Install 4 new insulators to the cylinder head.
b. Install the 2 No. 1 delivery pipe spacers to the cylinder head.

NOTE: Be careful of the installation direction of the delivery pipe spacer.

c. Install the fuel delivery pipe together with the 4 fuel injectors, and then temporarily tighten the 3 bolts.

NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe.

d. Check that the fuel injectors rotate smoothly. If the fuel injectors do not rotate, replace the O-ring.
e. Retighten the 3 bolts to the specified torque.

Torque:
19 N.m (194 kgf.cm, 14 ft.lbf) for bolt A

9.0 N.m (92 kgf.cm, 80 in.lbf) for bolt B

f. Connect the fuel tube to the fuel delivery pipe.

1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube to the fuel delivery pipe.

NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this work.
- After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling them.

2. Install the No. 1 fuel pipe clamp.

3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
4. INSTALL RESERVOIR BRACKET

a. Temporarily install the reservoir bracket with the bolt labeled 1 in the illustration.
b. Tighten the 3 bolts to the specified torque in the sequence shown in the illustration.

Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)

c. Install the connector clamp.
d. Install the wire harness clamp.
e. Install the No. 2 fuel vapor feed hose to the hose clamp.

5. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

a. Install the reservoir with the 2 bolts.

Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)

b. Connect the switch connector.

6. INSTALL AIR CLEANER ASSEMBLY
7. INSTALL FRONT OUTER COWL TOP PANEL SUBASSEMBLY

a. Install the panel with the 7 bolts.

Torque:6.4 N.m (65 kgf.cm, 57 in.lbf)

b. Connect the 4 wire harness clamps.
c. Install the No. 2 engine room relay block with the 2 bolts.

Torque: 8.4 N.m (86 kgf.cm, 74 in.lbf)

8. INSTALL WINDSHIELD WIPER MOTOR AND LINK
a. Install the windshield wiper motor and link.

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. INSPECT FOR FUEL LEAK
11. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.