Fuel Injector: Service and Repair

Fuel Injector:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. DRAIN ENGINE COOLANT
4. REMOVE COOL AIR INTAKE DUCT SEAL
5. REMOVE ENGINE ROOM SIDE COVER LH
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE FRONT SUSPENSION CENTER UPPER BRACE
8. REMOVE V-BANK COVER SUB-ASSEMBLY
9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
10. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

a. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly. (*1)
b. Disconnect the vapor feed hose. (*2)
c. Disconnect the throttle with motor body assembly connector and clamp. (*3)

d. Disconnect the No. 1 ventilation hose. (*4)
e Disconnect the union to check valve hose. (*5)

f. Remove the bolt and vacuum hose clamp.

g. Disconnect the connector.

h. Using a 5 mm socket hexagon wrench, remove the 4 bolts. (*1)
i. Remove the 2 nuts, 2 bolts and intake air surge tank. (*2)
j. Remove the gasket from the intake air surge tank.

11. DISCONNECT FUEL TUBE SUB-ASSEMBLY

a. Remove the No. 2 fuel pipe clamp.
b. Pinch the tube connector and then pull out the fuel pipe.

NOTE:
- Check that there is no dirt or other foreign objects around the connector disconnecting it. Clean the connector as necessary.
- It is necessary to prevent mud or dirt from entering the quick connector.
- If mud or dirt gets in the connector, the O-rings may not seal properly.
- Only disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and the connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.

12. REMOVE FUEL INJECTOR ASSEMBLY

a. Disconnect the 6 fuel injector connectors.

b. Remove the 5 bolts and fuel delivery pipe together with the 6 fuel injectors.

NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

c. Remove the 6 insulators from the intake manifold.

d. Pull out the fuel injectors from the fuel delivery pipe.

e. Remove the 6 O-rings from the injectors.

INSTALLATION

1. INSTALL FUEL INJECTOR ASSEMBLY

a. Apply a light coat of spindle oil or gasoline to new Orings, and install them to each injector.

b. Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts the O-ring.
c. Push the fuel injector while turning it to install the injector in the fuel delivery pipe.
d. Position the fuel injector connector outward.

NOTE:
- Be careful not to twist the O-ring.
- After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.

e. Install 6 new insulators to the intake manifold.

f. Place the fuel delivery pipe which has the 6 fuel injectors installed to it in position on the intake manifold.

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

g. Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

NOTE: After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.

h. Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

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

i. Connect the 6 fuel injector connectors.

2. CONNECT FUEL TUBE SUB-ASSEMBLY

a. Push in the tube connector onto the pipe until the tube connector makes a "click" sound.

NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

b. Install the No. 2 fuel pipe clamp.

3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTE: DO NOT apply oil to the bolts listed.

a. Install a new gasket to the intake air surge tank.
b. Using a 5 mm hexagon socket wrench, install the 4 bolts. (*1)

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

c. Install the intake air surge tank with the 2 nuts and 2 bolts. (*2)

Torque:
Nut 16 N.m (163 kgf.cm, 12 ft.lbf)
Bolt 21 N.m (214 kgf.cm, 15 ft.lbf)

d. Connect the connector.

e. Install the vacuum hose clamp with the bolt.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

f. Connect the union to check valve hose. (*1)
g. Connect the No. 1 ventilation hose. (*2)

h. Install the clamp and connect the throttle with motor body assembly connector. (*3)
i. Connect the vapor feed hose. (*4)
j. Connect the 2 water by-pass hoses to the throttle with motor body assembly. (*5)

4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
5. ADD ENGINE COOLANT
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
7. CHECK FOR ENGINE COOLANT LEAKS
8. CHECK FOR FUEL LEAKS
9. INSTALL V-BANK COVER SUB-ASSEMBLY
10. INSTALL FRONT SUSPENSION CENTER UPPER BRACE
11. INSTALL ENGINE ROOM SIDE COVER RH
12. INSTALL ENGINE ROOM SIDE COVER LH
13. INSTALL COOL AIR INTAKE DUCT SEAL
14. PERFORM INITIALIZATION
a. Perform initialization procedures

HINT: Some systems need initialization after reconnecting the cable to the negative battery terminal.