Fuel Injector: Service and Repair

Fuel Injector Assy Part 1:

Fuel Injector Assy Part 2:

REPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE V-BANK COVER
Remove the V-bank cover by removing the 2 nuts.

3. REMOVE AIR CLEANER INLET NO.1
4. REMOVE INTAKE AIR CONNECTOR PIPE
a. Disconnect the air hose and ventilation hose No.1.
b. Remove the intake air connector pipe by removing the bolt and hose clamp.

5. REMOVE V-BANK COVER BRACKET NO.1
6. REMOVE V-BANK COVER BRACKET NO.2
7. REMOVE V-BANK COVER BRACKET NO.3
8. REMOVE V-BANK COVER BRACKET NO.4
9. REMOVE VACUUM SWITCHING VALVE ASSY
10. SEPARATE ENGINE WIRE
11. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
a. Disconnect the fuel delivery pipe and the fuel pipe by removing the both of right and left pulsation dampers.
b. Remove the gasket.




12. REMOVE FUEL DELIVERY PIPE SUB-ASSY
a. Remove the installation bolts of the water bypass pipe No.1 and No.2.
b. Disconnect the connector.
c. Remove the 2 bolts, then the fuel delivery pipe No.1 by pulling it straight upward holding the both ends.

13. FUEL DELIVERY PIPE SUB-ASSY NO.2
a. Disconnect the connector.
b. Remove the 2 bolts, then the fuel delivery pipe No.2 by pulling it straight upward holding the both ends.

14. REMOVE FUEL INJECTOR ASSY
a. Remove the injector from the intake manifold.

NOTE: Do not put any force to the injector in the horizontal direction, because the O-ring might be stuck.

b. Remove the O-ring, grommet and vibration insulator from the injector.




15. INSTALL FUEL INJECTOR ASSY
a. Install a new grommet and vibration insulator to the injector.
b. Check that there is no foreign object stuck nor damage in the groove of the O-ring of the injector. Apply some gasoline to new O-ring, and install it to the injector.
c. Install the injector to the delivery pipe, rotating the injector both ways.
d. Check that the injector can rotate smoothly.

NOTE: When the injector cannot rotate smoothly, the O-ring might engage with something. In case of that, the operation should be started after the injector has been removed then the O-ring has been replaced with a new one once again.

16. INSTALL FUEL DELIVERY PIPE SUB-ASSY NO.2
a. Install the injector with delivery pipe to the intake manifold.
b. Under the above condition, turn the injector both ways by approximately 45 degrees.
c. Inserting a spacer in between, install the delivery pipe with injector by 2 bolts.

Torque: 21 Nm (2O4 kgf.cm, 14 ft.lbf)

17. INSTALL FUEL DELIVERY PIPE SUB-ASSY
a. Install the injector with delivery pipe to the intake manifold.
b. Under the above condition, turn the injector both ways by approximately 45 degrees.
c. Inserting a spacer in between, install the delivery pipe with injector by 2 bolts.

Torque: 21 Nm (204 kgf.cm, 14 ft.lbf)




18. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY
Inserting 2 new gaskets in between, install the fuel main hose the fuel pressure pulsation damper.

Torque: 39 Nm (400 kgf.cm, 29 ft.lbf)

19. INSTALL ENGINE WIRE
20. INSTALL VACUUM SWITCHING VALVE ASSY

Torque: 7.5 Nm (80 kgf.cm, 66 in.lbf)

21. INSTALL V-BANK COVER BRACKET NO.4

Torque: 7.5 Nm (80 kgf.cm, 66 in.lbf)

22. INSTALL V-BANK COVER BRACKET NO.3

Torque: 7.5 Nm (80 kgf.cm, 66 in.lbf)

23. INSTALL V-BANK COVER BRACKET NO.2

Torque: 7.5 Nm (80 kgf.cm, 66 in.lbf)

24. INSTALL V-BANK COVER BRACKET NO.1

Torque: 7.5 Nm (80 kgf.cm, 66 in.lbf)

25. INSTALL INTAKE AIR CONNECTOR PIPE
a. Install the intake air connector pipe with the bolt and the hose clamp.

Torque:
4 Nm (40 kgf.cm, 35 in.lbf) (hose clamp)
5 Nm (50 kgf.cm, 44 in.lbf) (bolt)

b. Connect the air hose and the ventilation hose NO.1 together.

26. INSTALL AIR CLEANER INLET NO.1
27. INSPECT FUEL LEAK
28. INSTALL V-BANK COVER

Torque: 5 Nm (5O kgf.cm, 44 in.lbf)