Fuel Injector: Service and Repair
REMOVAL1. REMOVE V-BANK COVER
a. Using a 5 mm hexagon wrench remove the 3 cap nuts.
b. Loosen the V-bank cover fastener counterclockwise.
c. Remove the V-bank cover.
2. REMOVE AIR CLEANER HOSE WITH RESONATOR
3. REMOVE AIR INTAKE CHAMBER ASSEMBLY
4. DISCONNECT INJECTOR CONNECTORS
5. REMOVE AIR ASSIST HOSES AND PIPE
6. DISCONNECT No.1 FUEL PIPE
a. Remove the fuel hose clamp.
b. Disconnect the No.1 fuel pipe (fuel tube connector) from the fuel filter outlet.
CAUTION:
^ Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions.
^ As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment.
7. REMOVE DELIVERY PIPES AND INJECTORS
NOTE:
- Be careful not to drop the injectors when remove the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.
a. Remove the 5 bolts and delivery pipes together with the 6 injectors and No.1 fuel pipe.
b. Remove the 4 spacers from the intake manifold.
c. Pull out the 6 injectors from the delivery pipes.
d. Remove the 2 O-rings and 2 grommets from each injector.
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES
a. Install new insulator and grommet to each injector.
b. Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector.
c. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches an O-ring of the injector.
d. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors.
e. Position the injector connector outward.
f. Place the 4 spacers in position on the intake manifold.
g. Apply a light coat of spindle oil or gasoline on the place where a intake manifold touches an O-ring of the injector.
h. Place the delivery pipes and fuel pipe together with the 6 injectors in position on the intake manifold.
i. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold.
j. Temporarily install the bolt holding the No.1 fuel pipe to the intake manifold.
k. 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.
l. Position the injector connector outward.
m. Tighten the 4 bolts holding the delivery pipes to the intake manifold.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
n. Tighten the bolt holding the No.1 fuel pipe to the intake manifold.
Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf)
2. CONNECT NO.1 FUEL PIPE
a. Align the alignment marks (white paint) on the No.1 fuel pipe.
b. Connect the No.1 fuel pipe (fuel tube connector) to the fuel filter.
CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions.
c. Surely install the fuel hose clamp to the fuel filter with "click" sound.
d. After installing the clamp, check that the clamp is fixed by pulling up the clamp.
3. INSTALL AIR ASSIST HOSES AND PIPE
4. CONNECT INJECTOR CONNECTORS
5. INSTALL AIR INTAKE CHAMBER ASSEMBLY
6. INSTALL AIR CLEANER HOSE WITH RESONATOR
7. INSTALL V-BANK COVER
a. Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts.
b. Press down the V-bank cover fastener.
8. CHECK FOR FUEL LEAKS