Fuel Injector: Service and Repair

REMOVAL

CAUTION: Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.

1. DISCHARGE FUEL SYSTEM PRESSURE

CAUTION:
- Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
- Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.

a. Disconnect the cable from the negative (-) battery terminal.

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

b. Disconnect the fuel pump connector.
c. Connect the cable to the negative (-) battery terminal.
d. Start the engine. After the engine has stopped on its own, turn the engine switch off.

HINT: DTC P0171/P0172 (system too lean) may be set.

e. Crank the engine again, then check that the engine does not start.
f. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
g. Connect the fuel pump connector.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE COOL AIR INTAKE DUCT SEAL
4. REMOVE ENGINE UNDER COVER
5. DRAIN ENGINE COOLANT
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE V-BANK COVER
8. DISCONNECT NO. 2 VENTILATION HOSE
9. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
10. DISCONNECT COLD START INJECTOR
11. DISCONNECT WATER BY-PASS HOSE
12. DISCONNECT HEATER WATER INLET HOSE

a. Disconnect the hose from the water hose joint.

13. DISCONNECT HEATER WATER OUTLET HOSE

a. Disconnect the hose from the pipe.

14. REMOVE ENGINE REAR COVER

a. Remove the 3 clips and engine rear cover.

15. DISCONNECT UNION TO CHECK VALVE HOSE

a. Disconnect the hose from the surge tank.

16. DISCONNECT VENTILATION HOSE

a. Disconnect the ventilation hose from the ventilation valve.

17. DISCONNECT FUEL MAIN TUBE

a. Remove the fuel pipe clamp.

b. Pinch and pull the fuel tube's connector to disconnect it from the fuel main pipe.

NOTE:
- Check for foreign matter in the fuel tube around the fuel tube's connector. Clean it if necessary. Foreign matter can affect the O-ring's ability to seal the connector and fuel main pipe.
- Do not use any tools to separate the connector and pipe.
- Do not forcefully bend or twist the hose.
- Keep the connector and pipe free from foreign matter.
- If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
- Put the connector in a plastic bag to prevent damage and contamination.

18. REMOVE INTAKE AIR SURGE TANK

a. Disconnect the throttle motor connector.
b. Disconnect the IACV connector.
c. Disconnect the wire harness clamp from the surge tank.
d. Remove the 2 bolts and intake manifold stay.
e. Disconnect the 2 wire harness clamps from the surge tank stays.
f. Remove the 4 bolts and 2 surge tank stays.
g. Remove the bolt and disconnect the water hose joint.

h. Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.

HINT: Cover the intake manifold port to prevent foreign matter from entering it.

19. REMOVE INTAKE MANIFOLD

a. Disconnect the DC motor connector for the SCV.
b. Disconnect the SCV position sensor connector.
c. Remove the 4 bolts, 4 nuts, intake manifold and gasket.

HINT: Cover the cylinder head intake port to prevent foreign matter from entering it.

20. REMOVE FUEL PRESSURE PULSATION DAMPER

a. Remove the fuel pressure pulsation damper from the fuel pump.

21. REMOVE NO. 1 FUEL PIPE

a. Disconnect the fuel pipe hose.
b. Remove the 2 bolts and fuel pipe.

22. DISCONNECT NO. 2 FUEL PIPE
23. REMOVE HIGH PRESSURE SIDE FUEL PUMP

24. REMOVE NO. 2 FUEL PIPE
a. Remove the fuel pipe from the fuel delivery pipe.

NOTE: Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.

25. REMOVE NO. 3 FUEL PIPE

a. Remove the bolt and fuel pipe from the fuel delivery pipe.

NOTE: Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.

26. REMOVE NO. 2 FUEL DELIVERY PIPE

a. Disconnect the 3 wire harness clamps.
b. Remove the 2 bolts and 2 nuts.

c. With the connectors still connected, disconnect the delivery pipe.

NOTE:
- Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).
- Be extremely careful not to touch or strike the tips of the injectors.
- Pull and remove the fuel pipe in a straight line without tilting it.

d. Disconnect the 3 connectors from the 3 injectors.
e. Remove the 3 injector vibration insulators from the cylinder head.

27. REMOVE NO. 1 FUEL DELIVERY PIPE

a. Disconnect the 2 wire harness clamps.
b. Remove the 2 bolts and 2 nuts.

c. With the connectors still connected, disconnect the No. 2 fuel delivery pipe.

NOTE:
- Be extremely careful not to touch or strike the tips of the injectors.
- Pull and remove the fuel pipe in a straight line without tilting it.

d. Disconnect the 3 connectors from the 3 injectors.
e. Remove the 3 injector vibration insulators from the cylinder head.

28. REMOVE FUEL INJECTOR

a. Remove the injectors from the delivery pipe.

NOTE: Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.

b. Remove the nozzle holder clamp from the injector.
c. Remove the E-ring, O-ring, No. 1 backup ring, No. 2 backup ring and No. 3 backup ring from the injector.

29. REMOVE FUEL INJECTOR SEAL

a. Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.

NOTE:
- Excessively pinching the injector seal may damage the groove of the injector.
- Be extremely careful not to touch or strike the tips of the injectors.
- If an injector is dropped, replace it with a new one.

b. Remove the 2 injector seals from the injector.

INSTALLATION

1. INSTALL FUEL INJECTOR SEAL

a. Apply engine conditioner to the injector area shown in the illustration. Using a cloth, clean carbon deposits from the injector and its grooves.

NOTE:
- Do not clean the tip of the injector.
- Do not use a wire brush to clean the injector.
- If an injector is dropped, replace it with a new one.
- Be extremely careful not to touch or strike the tips of the injectors.

b. Apply engine oil to the injector contact surface of SST (guide). Then attach SST (guide) to the injector with the tapered inner portion facing the tip of the injector, as shown in the illustration.

SST 09260-39015 (09268-03020)

c. Install a new injector seal to SST (holder).

SST 09260-39015 (09268-03010)

NOTE: Be careful not to install the injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.

d. Install SST (holder with injector seal) to the tip of the injector. Using your fingers, slide the seal downward into the injector groove (injector connector side), as shown in the illustration.

SST 09260-39015 (09268-03010, 09268-03020)

HINT: Check that the seal covers the circumference of the injector groove as shown in the illustration.

e. Using SST (holder), gently press downward on the injector seal (injector connector side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.

SST 09260-39015 (09268-03010, 09268-03020)

NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

HINT:
- When using SST (guide) to settle the seal into the groove: SST (guide) only needs to be slid upward to the position labeled A in the illustration.
- After using SST (guide) to settle the seal into the groove: Return SST (guide) to its position labeled B in the illustration.

f. Install a new injector seal to the injector groove (injector tip side) as shown in the illustration.

SST 09260-39015 (09268-03010, 09268-03020)

g. Check that the seal covers the circumference of the injector groove as shown in the illustration.

SST 09260-39015 (09268-03010, 09268-03020)

NOTE: Make sure the seal does not slip into the welded groove of the injector shown in the illustration. If it does, replace it with a new one.

h. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.

SST 09260-39015 (09268-03020)

NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

HINT:
- Set SST (guide) so that its bottom surface and seal are flush.
- If there is difficulty sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.

i. Using SST (holder), gently press downward on the injector seal (injector tip side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.

SST 09260-39015 (09268-03010, 09268-03020)

NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

j. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.

SST 09260-39015 (09268-03020)

NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

HINT:
- Set SST (guide) so that its bottom surface and the seal's bottom surface are flush.
- If there is difficulty sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.

k. After installing the seals, check that the seal is not scratched, deformed or protruding from the injector groove.

NOTE: If scratched, deformed or protruding from the groove, replace it with a new one.

2. INSTALL FUEL INJECTOR

a. Install a new O-ring, new backup rings (No. 1, No. 2, No. 3) and new E-ring to the fuel injector as shown in the illustration.

NOTE:
- Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
- Check that the installation direction of the No. 1 and No. 2 backup ring are correct.
- Make sure the backup rings and O-ring are installed in the correct order.
- Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
- After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

b. Install the injector nozzle holder clamp.

c. Apply gasoline to the O-ring. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.

NOTE:
- Make sure there is no gap between the delivery pipe and clamp.
- Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
- Insert the injector straight into the delivery pipe without tilting it.

3. INSTALL NO. 1 FUEL DELIVERY PIPE

a. Install a new injector vibration insulator to the cylinder head.
b. Apply lubricant to the installation hole of the injector.

c. Insert the stud bolt into the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.

NOTE:
- If an injector is dropped, replace it with a new one.
- Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
- Be extremely careful not to touch or strike the tips of the injectors.
- When inserting the fuel delivery pipe, push it in evenly without tilting it.

d. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)

e. Connect the 3 connectors and 2 clamps.

4. INSTALL NO. 2 FUEL DELIVERY PIPE

a. Install a new injector vibration insulator to the cylinder head.
b. Apply lubricant to the installation hole of the injector.

c. Insert the stud bolt into the delivery pipe until the screw threads protrude enough so that a nut can be attached.

NOTE:
- If an injector is dropped, replace it with a new one.
- Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
- Be extremely careful not to touch or strike the tips of the injectors.
- When inserting the fuel delivery pipe, push it in evenly without tilting it.

a. Install a new O-ring, new backup rings (No. 1, No. 2) and new E-ring to the fuel injector as shown in the illustration.

NOTE:
- Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
- Check that the installation directions of the No. 1 and No. 2 backup ring are correct.
- Make sure the backup rings and O-ring are installed in the correct order.
- Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
- After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
- Check that the fuel pipe installation end is not contaminated with foreign matter and is not damaged.

b. Apply gasoline to the O-ring.

c. Using your hand, press the fuel pipe and delivery pipe together until there is no gap between them. Then install the No. 3 fuel pipe with the 4 bolts.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

6. CONNECT NO. 2 FUEL PIPE

a. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown in the illustration.

NOTE:
- Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
- Check that the installation directions of the No. 1 and No. 2 backup rings are correct.
- Make sure the backup rings and O-ring are installed in the correct order.
- Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
- After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
- Check that the No. 3 fuel pipe installation end is not contaminated with foreign matter and is not damaged.

b. Apply gasoline to the O-ring and connect the fuel pipe to the delivery pipe.

NOTE: Do not install the bolt at this time.

7. INSTALL HIGH PRESSURE SIDE FUEL PUMP
8. INSTALL NO. 2 FUEL PIPE

a. Install the fuel pipe to the delivery pipe with the 2 bolts.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

9. INSTALL NO. 1 FUEL PIPE

a. Install the fuel pipe with the 2 bolts.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

b. Connect the No. 1 fuel pipe hose.

10. INSTALL FUEL PRESSURE PULSATION DAMPER

a. Install a new gasket and the fuel pulsation damper to the fuel pump.

Torque: 40 N.m (408 kgf.cm, 28 ft.lbf)

11. INSTALL INTAKE MANIFOLD

a. Install a new gasket and the intake manifold with the 4 bolts and 4 nuts.

Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)

b. Connect the SCV position sensor connector.
c. Connect the DC motor connector for the SCV.

12. INSTALL INTAKE AIR SURGE TANK

a. Install a new gasket to the intake air surge tank.
b. Install the intake air surge tank with the 2 nuts.

Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)

c. Using a 5 mm hexagon socket wrench, install the 7 bolts.

Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)

d. Install the 2 surge tank stays with the 4 bolts.

Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)

e. Connect the 2 wire harness clamps.
f. Connect the water hose joint with the bolt.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

g. Install the intake manifold stay with the 2 bolts.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

h. Connect the wire harness clamp to the intake surge tank.
i. Connect the IACV connector.
j. Connect the throttle motor connector.

13. CONNECT FUEL MAIN TUBE

NOTE: Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.

a. Connect the connector to the fuel main pipe. Push the two parts together firmly until a "click" sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.

b. Check that the connector and fuel main pipe are securely connected by trying to pull them apart.

c. Install the fuel pipe clamp.

14. CONNECT VENTILATION HOSE

a. Connect the ventilation hose to the ventilation valve.

15. CONNECT UNION TO CHECK VALVE HOSE

a. Connect the hose to the surge tank.

16. INSTALL ENGINE REAR COVER

a. Install the engine rear cover with the 3 clips.

17. CONNECT HEATER WATER OUTLET HOSE

a. Connect the hose to the pipe.

18. CONNECT HEATER WATER INLET HOSE

a. Connect the hose to the pipe.

19. CONNECT WATER BY-PASS HOSE
20. REMOVE COLD START INJECTOR
21. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
22. CONNECT NO. 2 VENTILATION HOSE
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
24. ADD ENGINE COOLANT
25. CHECK FOR COOLANT LEAKAGE
26. CHECK FOR FUEL LEAKAGE
a. Start the engine, and check that there are no fuel leaks after performing maintenance anywhere on the system.

27. CHECK FOR ENGINE OIL LEAKAGE
a. Start the engine, and check that there are no oil leaks after performing maintenance.

28. INSTALL V-BANK COVER
29. INSTALL ENGINE ROOM SIDE COVER RH
30. INSTALL COOL AIR INTAKE DUCT SEAL
31. INSTALL ENGINE UNDER COVER
32. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

33. WARM UP ENGINE
a. After the engine is warmed up, check that the maintained parts operate normally.