Fuel Injector: Service and Repair

COMPONENTS

REMOVAL

1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR PIPE
3. DISCONNECT ACCELERATOR CABLE FROM ENGINE

4. DISCONNECT ENGINE WIRE PROTECTOR FROM UPPER INTAKE MANIFOLD AND BEARING CAP




a. Remove and disconnect these parts:
1. VSV connector for EVAP
2. PCV hose from upper intake manifold
3. EVAP hose from VSV for EVAP
4. Air inlet hose from air tube
5. No.2 V-bank cover bracket from No.1 engine hanger
6. VSV for EVAP from upper intake manifold
7. Accelerator cable clamp from upper intake manifold
8. No.3 V-bank cover bracket from upper intake manifold




b. Remove the 4 bolts, and disconnect the engine wire protector from the upper intake manifold and camshaft bearing cap.

5. DISCONNECT ENGINE WIRE FROM RH DELIVERY PIPE
Disconnect the 2 wire clamps on the engine wire from the brackets on the delivery pipe

6. REMOVE FUEL PRESSURE PULSATION DAMPERS

7. REMOVE DELIVERY PIPES AND INJECTORS

NOTE:
- Be careful not to drop the injectors when removing the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.




a. Remove the bolt, and disconnect the VSV bracket for the ACIS from the upper intake manifold.
b. Remove the 2 nuts and accelerator cable bracket.
c. Disconnect the 8 injector connectors.




d. Remove the 4 nuts holding the delivery pipes to the lower intake manifold.
e. Remove the 2 delivery pipes, 8 injectors and 4 spacers.
f. No.5, No.6, No.7 and No.8 Injectors:
Remove the injector cover from each injector.
g. Remove the 2 O-ring grommet and insulator from each injector.

INSTALLATION

1. INSTALL INJECTORS AND DELIVERY PIPES

NOTE: Be careful not to drop the injectors when installing the delivery pipes.

Pay attention to put any hung load on the injector to and from the side direction.




a. Install a new grommet and new insulator to each injector.
b. Apply a light coat of gasoline to 2 new O-ring and install them to each injector.




c. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 8 injectors.
d. Position injector connector outward.




e. Place the 4 spacers on the intake manifold.
f. Place the 2 delivery pipes and injectors assemblies on the lower intake manifold.
g. Temporarily install the 4 nuts.




h. Check that the injectors rotate smoothly.

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

i. Position injector connector outward.
j. Tighten the 4 nuts holding the delivery pipes to the lower intake manifold.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

k. Connect the 8 injectors connectors.




I. Install the accelerator cable bracket with the 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

m. Install the VSV bracket for the ACIS with the bolt.

2. INSTALL FUEL PRESSURE PULSATION DAMPERS

3. INSTALL ENGINE WIRE TO LH DELIVERY PIPE
Install the 2 wire clamps on the engine wire to the brackets on the delivery pipe.

4. INSTALL ENGINE WIRE PROTECTOR




a. Install the engine wire protector with the 4 bolts.




b. Install and connect these parts:
1. VSV connector for EVAP
2. PCV hose to upper intake manifold
3. EVAP hose to VSV for EVAP
4. Air inlet hose to air tube
5. No.2 V-bank cover bracket to No.1 engine hanger
6. VSV for EVAP to upper intake manifold
7. Accelerator cable clamp to upper intake manifold
8. No.3 V-bank cover bracket to upper intake manifold

5. INSTALL ACCELERATOR CABLE
6. INSTALL INTAKE AIR CONNECTOR PIPE
7. INSTALL V-BANK COVER