Fuel Injector: Service and Repair

COMPONENTS FOR REMOVAL AND INSTALLATION

REMOVAL
1. Drain engine coolant.
2. Disconnect control cables and intake air connector pipe.




3. Remove Exhaust Gas Recirculation (EGR) pipe.
- Loosen the union nut of the EGR pipe.
- Remove the 2 bolts, EGR pipe and gasket.
4. Disconnect EGR gas temperature sensor connector.




5. Disconnect throttle body bracket from throttle body and cylinder head.
6. Remove throttle body with intake air connector.
- Disconnect these hoses:
- PCV hose from intake air connector
- 3 vacuum hoses from No. 2 vacuum pipe




- Disconnect these connectors:
- w/TRAC:
Sub-throttle actuator connector
- w/TRAC:
Sub-throttle position sensor connector (3) IAC valve connector
- Throttle position sensor connector
- VSV connector for EGR




- Remove the nut holding the VSV to the chamber stay.
- Remove the 4 bolts and 2 nuts holding the intake air connector to the intake chamber.




- Disconnect the vacuum hose (from the actuator) from the No.1 vacuum pipe.
- Disconnect the 2 water bypass hoses from the throttle body.




- Remove the throttle body together with the intake air connector and gasket.




7. Disconnect fuel inlet pipe from delivery pipe.
- Remove the 2 nuts and disconnect the No. 2 vacuum pipe.




- Remove the union bolt and 2 gaskets, and disconnect the fuel pipe.

CAUTION:
- Put a shop towel under the delivery pipe.
- Slowly loosen the union bolt.




8. Disconnect fuel return pipe from fuel pressure regulator.
- Remove the bolt holding the fuel pipe to the intake manifold.
- Remove the union bolt and 2 gaskets, and disconnect the fuel pipe from the pressure regulator.

CAUTION:
- Put a shop towel under the pressure regulator.
- Slowly loosen the union bolt.




9. Remove air intake chamber stays.
- Remove the bolt, nut and intake chamber stay. Remove the No.1 and No. 2 stays.




10. Disconnect vacuum sensing hose from pressure regulator.
11. Disconnect injector connectors.




12. Disconnect actuator for ACIS.
- Remove the 2 bolts and disconnect the actuator.




- Wrap the actuator with adhesive tape and attach it to the intake chamber.

NOTICE: Do not apply any force on the actuator rod and prevent the rod clip from detaching.




13. Remove delivery pipe and injectors.
- Remove the 3 bolts and delivery pipe together with the 6 injectors.

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

- Pull out the 6 injectors from the delivery pipe.
- Remove the O-rings and grommets from each injector.
- Remove the 3 spacers from the intake manifold.




INSTALLATION
1. Install injectors and delivery pipe.
- Install 2 new grommets to each injector.
- Apply a light coat of gasoline to 2 new O-rings and install them to each injector.




- While turning the injector clockwise and counterclockwise, push it to the delivery pipe.
- Install the 6 injectors.
- Position the injector connector outward.




- Place the for and 3 spacers in position on the intake manifold.




- Place the 6 injectors together with the delivery pipe and 3 bolts in position on the intake manifold.




- Temporarily install the 3 bolts holding the delivery pipe to the intake manifold.




- Check that the injectors rotate smoothly.

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

- Position the injector connector upward.




- Tighten the 3 bolts holding the delivery pipe to the intake manifold.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)




2. Install actuator for ACIS.
- Install the actuator with the 2 bolts.

Torque: 6.8 N.m (70 kgf.cm. 61 in..lbf)

- Inspect the intake air control valve.




3. Connect injector connectors.

HINT: The No. 1, No. 3 and No. 5 injector connectors are dark gray and the No. 2, No. 4 and No. 6 injector connectors are gray.

4. Connect vacuum sensing hose.




5. Install air intake chamber stays.
- Install the intake chamber stay with the bolt and nut.
- Install the No. 1 and No.2 stays.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

HINT: The No. 1 stay is marked with "F" and No. 2 stay is marked with "R".




6. Connect fuel return pipe to fuel pressure regulator.
- Connect the fuel pipe with 2 new gaskets and the union bolt.

Torque: 27 N.m (280 kgf.cm. 20 ft.lbf)

- Install the bolt holding the fuel pipe to the intake manifold.




7. Connect fuel inlet pipe to delivery pipe.
- Connect the fuel pipe with 2 new gaskets and the union bolt.

Torque: 42 N.m (420 kgf.cm, 30 ft.lbf)




- Install the No. 2 vacuum pipe with the 2 nuts.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)




8. Install throttle body with intake air connector.
- Place the new gasket so the protrusion face the intake chamber, and set the throttle body together with the intake air connector.




- Connect the 2 water bypass hoses to the throttle body.
- Connect the vacuum hose (from the actuator) to the No.1 vacuum pipe.
- Install the intake air connector with the 4 bolts and 2 nuts.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)




- Install the nut holding the VSV to the chamber stay.




- Connect these connectors:
- w/TRAC:
Sub-throttle actuator connector
- w/ TRAC:
Sub-throttle position sensor connector
- IAC valve connector
- Throttle position sensor connector
- VSV connector for EGR




- Connect these hoses:
- PCV hose to intake air connector
- 3 vacuum hoses to No. 2 vacuum pipe
9. Install throttle body bracket.
- Install the throttle body bracket with the 4 nuts.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)

10. Connect EGR gas temperature sensor connector.




11. Install EGR pipe.
- Temporarily install the union nut of the EGR pipe.
- Install a new gasket and the EGR pipe with the 2 bolts.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)

- Tighten the union nut of the EGR pipe.

Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

12. Install intake air connector pipe and connect control cables.

13. Fill with engine coolant.
14. Check for fuel leaks.