Fuel Injector: Service and Repair

Inspection

1. Turn the ignition switch OFF.
2. Disconnect the injector connector.
3. Measure resistance between the injector terminals 1 and 2.
4. Check that the resistance is within the specification.

Specification:Refer to "Specification"

Removal

WARNING:
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Release the residual pressure in fuel line .

CAUTION:
When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.

3. Remove the delivery pipe & injector assembly .
4. Remove the retaining clip (A), and then separate the injector from the delivery pipe.






Installation

CAUTION:
Do not reuse the injector retaining clip, O-ring, backup ring, washer seal or combustion seal ring. Once an injector is removed, the five components must be replaced with new ones.




1. Combustion seal
2. Washer seal
3. Backup ring
4. O-ring
5. Retaining clip

NOTE:
- Item 1,3 and 4 are supplied in a single kit.

CAUTION:
- Install the component with the specified torques.
- Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing.

CAUTION:
- Apply engine oil to the injector O-ring.

CAUTION:
- Do not reuse the delivery pipe mounting bolts. Once the delivery pipe is removed, the bolts must be replaced with new ones.

CAUTION:
- When inserting the injector, be careful not to damage the injector tip.

CAUTION:
- When replacing the washer seal, the steal plate (A) part should be faced the cylinder installation part and the rubber plate (B) part should be faced the injector body part.





CAUTION:
- Do not reuse the combustion seal.
- Be careful not to apply engine oil on the combustion seal ring.

CAUTION:
- Avoid dropping the fuel pipe (including injectors) or bumping it into any hard objects since damage to the internal components may occur. If necessary, visually inspect and confirm proper operation with performance tests prior to reuse.
- Before installing the injector into the cylinder head, clean the injector hole and avoid contaminants from entering inside the injector hole. When installing the injector, avoid bumping the injector tip into any of the surrounding components since the tip may become damaged from the impact.
- When fastening the three fuel delivery pipe mounting bolts, fully hand-tighten first, and then tighten in the proper sequence (1 -> 2 -> 3) in several cycles up to the specified torque. The delivery pipe should move less than 1/8 inch (approx.3mm), whenever each bolt is tightened.




1. Installation is reverse of removal.

Replacement

The injector combustion seal should be replaced new one to prevent leakage after removing the injector.
1. Remove the combustion seal (A) with a wire cutter.





CAUTION:
Grip the sealing ring carefully, pull it to form a small loop and then cut it.
Be careful not to damage the surface of the valve sleeve with the wire cutter.

2. Before the assembly of the sealing ring the groove must be cleaned using a clean cloth.
Any coking of the injector sealing surface must be carefully removed with a brass-wire brush.





CAUTION:
The surfaces of the new sealing ring must be clean and free of grease.

3. Place the combustion seal on the cone and pull downward on the seal as indicated in the photo.





NOTE:

Your fingers will work better for installing the Combustion Seal overthe cone.
4. Pull the seal downward until it is near the bottom of the cone as shown in the photo.




5. Place the cone (with seal) on the end of the injector.
Place the sizing tool (SST No.: 09353-2B000) overthe cone. Make sure the tool flange is toward the seal as shown.
Press down on the tool to work the seal over the injector and into the groove.




6. Because the seal will stretch as it goes over the end of the injector, it will be a bit oversized after installation.
By letting the injector and seal set for a few minutes, the seal may reduce in size.
Inspect the seal for damage before continuing.




7. Place the resizing tool (flange up) over the seal. Twist the tool slightly while pushing down over the seal. This should reduce the size of the seal.





CAUTION:
Be careful not to apply engine oil on the combustion seal ring.

8. Place injector into the head as shown.




9. Twist slightly while pressing the injector into position in the head.
This should complete the resizing of the seal.
Remove the injector and inspect the seal before completing the injector installation process.




10. If the injector comes with a protective steel washer held in place by a spring clip; both will have to be removed before installation.




11. Install the Washer Seal onto injector with the rubber side (stepped) toward the injector.




12. The stepped rubber side of the seal goes towards the injector.




13. The flat washer side of the seal goes towards the head.