Fuel Injector: Service and Repair

Fuel Injector Assy (Part 1):

Fuel Injector Assy (Part 2):

Fuel Injector Assy (Part 3):

REPLACEMENT

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE V-BANK COVER
a. Remove the 2 nuts and V-bank cover.

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

6. REMOVE V BANK COVER BRACKET NO.1
7. REMOVE V BANK COVER BRACKET NO.2
8. REMOVE V BANK COVER BRACKET NO.3
9. REMOVE V BANK COVER BRACKET NO.4
10. REMOVE PURGE VSV




11. DISCONNECT ENGINE WIRE
a. Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe.

12. DISCONNECT FUEL PRESSURE PULSATION DAMPER ASSEMBLY
a. Using a wrench, remove the 2 pressure pulsation dampers.
b. Remove the bolt, No. 2 fuel pipe and 4 gaskets.




13. REMOVE FUEL DELIVERY PIPE SUB ASSEMBLY
a. Remove the installation bolts of the water by pass pipe No. 1 and No. 2.
b. Disconnect the connector.
c. Remove the 2 bolts.
d. Remove the fuel delivery pipe No. 1 by pulling it straight upward holding both the ends.

14. REMOVE FUEL DELIVERY PIPE SUB ASSEMBLY NO.2
a. Disconnect the connector.
b. Remove the 2 bolts.
c. Remove the fuel delivery pipe No. 2 by pulling it straight upward holding both the ends.

15. REMOVE FUEL INJECTOR ASSEMBLY
a. Remove the injector from the intake manifold.

NOTE: Pull upward on the injector. Adding force in the horizontal direction may cause the O-ring to become stuck.

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




16. INSTALL FUEL INJECTOR ASSEMBLY
a. Install a new grommet and vibration insulator to the injector.
b. Check the injector's grooves (where O-rings are installed) for foreign matter or damage. Apply gasoline to 2 new O-rings and install them to the injector's grooves.
c. To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth. Install the 4 injectors.
d. Check that the injector can rotate smoothly.

NOTE: When the injector cannot rotate smoothly, the O-ring may be caught on something. Remove the injector, replace the faulty O-ring, and reinstall the injector.




17. INSTALL FUEL DELIVERY PIPE SUB ASSEMBLY 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) with the 2 nuts.

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

18. INSTALL FUEL DELIVERY PIPE SUB ASSEMBLY
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) with the 2 nuts.

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

19. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
a. Using a wrench, install 4 new gaskets and 2 fuel pulsation dampers together with the No. 2 fuel pipe to the delivery pipe.

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

b. Install the bolt to the fuel pipe sub assembly No. 2 clamp.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

c. Connect the fuel main tube.




20. INSTALL ENGINE WIRE
a. Install the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.

21. INSTALL PURGE VSV

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

22. INSTALL V BANK COVER BRACKET NO. 4

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)

23. INSTALL V BANK COVER BRACKET NO. 3

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)

24. INSTALL V BANK COVER BRACKET NO.2

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)

25. INSTALL V BANK COVER BRACKET NO. 1

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)

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

Torque: 4.0 N.m (40 kgf.cm, 35 in.lbf) for hose clamp
5.0 N.m (50 kgf.cm, 44 in.lbf) for bolt

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

27. INSTALL AIR CLEANER INLET NO.1
28. INSPECT FOR FUEL LEAKS
29. INSTALL V BANK COVER

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

30. CONNECT BATTERY NEGATIVE TERMINAL

NOTE: When disconnecting the negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected.