Fuel Injector: Service and Repair
REPLACEMENT1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
3. DRAIN ENGINE COOLANT
4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS)
5. REMOVE V-BANK COVER SUB-ASSY
6. REMOVE AIR CLEANER CAP SUB-ASSY
7. REMOVE EMISSION CONTROL VALVE SET
(a) Disconnect the 2 VSV connectors.
(b) Remove the wire harness clamp.
(c) Disconnect the fuel vapor feed hose No.1.
(d) Disconnect the fuel vapor feed hose No.2.
(e) Disconnect the 2 vacuum hoses.
(f) Remove the clamp.
(g) Remove the 2 nuts, then remove the emission control valve set.
8. REMOVE INTAKE AIR SURGE TANK
(a) Disconnect the throttle motor connector.
(b) Disconnect the water by-pass hose No.3.
(c) Disconnect the water by-pass hose No.2.
(d) Disconnect the union to check valve hose.
(e) Disconnect the ventilation hose.
(f) Remove the 2 nuts, then remove the pressure feed tube.
(g) Remove the 2 bolts, then remove the engine hanger No.1.
(h) Remove the 2 bolts, then remove the surge tank stay No.1.
(i) Remove the 2 bolts, then remove the surge tank stay No.2.
(j) Disconnect the bond cable No.1 connector.
(k) Using a socket hexagon wrench 8, remove the 4 bolts.
(l) Remove the 2 nuts, then remove the emission control valve bracket and intake air surge tank.
(m) Remove the gasket from the intake air surge tank.
9. SEPARATE FUEL PIPE SUB-ASSY NO.1
(a) Remove the fuel pressure pulsation damper and 2 gaskets.
(b) Remove the fuel pipe No.2 union bolt and 2 gaskets.
(c) Remove the bolt, then separate the fuel pipe No.1.
10. REMOVE FUEL INJECTOR ASSY
(a) Disconnect the 6 fuel injector connectors.
(b) Remove the 4 bolts, then remove the 2 fuel delivery pipes together with the 6 fuel injectors.
NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
(c) Remove the 4 delivery pipe No.1 spacers from the intake manifold.
(d) Remove the 6 insulators from the intake manifold.
(e) Pull out the fuel injector from the fuel delivery pipe.
11. INSTALL FUEL INJECTOR ASSY
(a) Install new grommets to each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to new O-rings, then install them to each fuel injector.
(c) Apply a light coat of spindle oil or gasoline to the place where the fuel delivery pipe contacts the 0-ring.
(d) Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
NOTICE:
- Be careful not to twist the O-ring.
- After installing the fuel injectors, check that they turn smoothly. If not, replace 0-ring with a new O-ring.
(e) Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
(f) Place the 2 fuel delivery pipes together with the 6 fuel injectors to the intake manifold.
NOTICE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
(g) Temporarily install the 4 bolts which attach the fuel delivery pipe to the intake manifold.
(h) Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause is incorrect installation of the O-ring. Replace it with a new one.
(i) Tighten the 4 bolts.
Torque: 10 N-m (102 kgf-cm, 7 ft-lbf)
(j) Connect the 6 fuel injector connectors.
12. INSTALL FUEL PIPE SUB-ASSY NO.1
(a) Install 2 new gaskets and fuel pipe No.2 union bolt.
Torque: 33 N-m (331 kgf-cm, 24 ft-lbf)
(b) Install 2 new gaskets and fuel pressure pulsation damper.
Torque: 33 N-m (331 kgf-cm, 24 ft-lbf)
(c) Install the fuel pipe No.1 with the bolt.
Torque: 20 N-m (199 kgf-cm, 14 ft-lbf)
13. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 N-m (286 kgf-cm, 21 ft-lbf)
(c) Using a socket hexagon wrench 8, tighten the 4 bolts.
Torque: 28 N-m (286 kgf-cm, 21 ft-lbf)
(d) Install the surge tank stay No.2 with the 2 bolts.
Torque: 20 N-m (199 kgf-cm, 14 ft-lbf)
(e) Install the surge tank stay No.1 with the 2 bolts.
Torque: 20 N-m (199 kgf-cm, 14 ft-lbf)
(f) Install the engine hunger No.1 with the 2 bolts.
Torque: 20 N-m (199 kgf-cm, 14 ft-lbf)
(g) Install the pressure feed tube with the 2 nuts.
Torque: 7.8 N-m (80 kgf-cm, 69 in.-lbf)
(h) Connect the ventilation hose.
(i) Connect the union to check valve hose.
(j) Connect the water by-pass hose No.2.
(k) Connect the water by-pass hose No.3.
(l) Connect the throttle motor connector.
14. INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N-m (82 kgf-cm, 71 in.-lbf)
15. INSTALL AIR CLEANER CAP SUB-ASSY
16. CHECK CONNECTION OF VACUUM HOSE
17. CONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
18. ADD ENGINE COOLANT
19. CHECK FOR ENGINE COOLANT LEAKS
20. CHECK FOR FUEL LEAKS
21. INSTALL V-BANK COVER SUB-ASSY
22. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS)
23. SYSTEM INITIALIZATION