Fuel Injector (for Direct Injection)

REMOVAL

1. PRECAUTION
2. DISCHARGE FUEL SYSTEM PRESSURE
3. 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.

4. REMOVE COOL AIR INTAKE DUCT SEAL
5. REMOVE ENGINE ROOM SIDE COVER LH
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE V-BANK COVER SUB-ASSEMBLY
8. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH
9. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH
10. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
11. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
14. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
15. DRAIN ENGINE COOLANT
16. DISCONNECT NO. 2 VENTILATION HOSE
17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
18. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY
19. REMOVE INTAKE AIR SURGE TANK
20. REMOVE INTAKE MANIFOLD

a. Disconnect the fuel tube from the delivery pipe subassembly.

NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not forcefully bend or twist the nylon tube.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.

b. Disconnect the 4 connectors.

c. Remove the 4 bolts, 4 nuts, intake manifold and gasket.

21. DISCONNECT WATER HOSE JOINT

a. Remove the bolt and disconnect the water hose joint.

22. REMOVE FUEL PRESSURE PULSATION DAMPER
23. REMOVE NO. 1 FUEL PIPE

a. Disconnect the No. 3 fuel hose from the No. 1 fuel pipe.
b. Disconnect the 2 fuel hoses.

c. Remove the 2 bolts and No. 1 fuel pipe.

24. DISCONNECT NO. 2 FUEL PIPE
25. REMOVE FUEL PUMP ASSEMBLY
26. 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.

b. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.

27. REMOVE NO. 3 FUEL PIPE

a. Remove the 4 bolts 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.

b. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.

28. 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 No. 2 fuel 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 injector connectors.
e. Remove the 3 injector vibration insulators from the cylinder head.

29. REMOVE NO. 1 FUEL DELIVERY PIPE

a. Disconnect the 2 wire harness clamps and fuel pressure sensor connector.

b. Remove the 2 bolts and 2 nuts.

c. With the connectors still connected, disconnect the No. 1 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 injector connectors.
e. Remove the 3 injector vibration insulators from the cylinder head.

30. REMOVE FUEL INJECTOR ASSEMBLY

a. Secure the delivery pipe between aluminum plates in a vise and pull out the injector in a straight line.

NOTE:
- Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
- For reinstallation, attach a tag or label to the injector shaft.

b. Remove the nozzle holder clamp from the injector.
c. Remove the O-ring, backup rings and E-ring from the fuel injector.

31. REMOVE FUEL INJECTOR SEAL

a. Using the tips 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.
- If an injector is dropped or the tips of the injectors are struck, 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 clean area shown in the illustration. Using a piece of 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 or the tips of the injectors are struck, replace it with a new one.

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. Slide the seal downward into the injector groove (injector connector side) with your fingers, 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 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.

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

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

NOTE: Make sure that 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.

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

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 it is difficult to slide 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 it is difficult to slide 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 the seal is scratched, deformed or protruding from the groove, replace it with a new one

2. INSTALL FUEL INJECTOR ASSEMBLY

a. Install a new O-ring, new backup rings (No. 1, No. 2, No. 3) and new E-ring to the 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 No. 1, No. 2 and No. 3 backup rings are installed in the correct direction.
- Make sure that 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 that there is no gap between the delivery pipe and clamp.
- Check that there is no foreign matter or damage to 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 new injector vibration insulators to the cylinder head.
b. Apply lubricant to the installation holes of the injectors.

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

NOTE:
- If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
- Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
- 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: 26 N.m (265 kgf.cm, 19 ft.lbf)

e. Connect the 3 connectors, 2 clamps and fuel pressure sensor connector.

4. INSTALL NO. 2 FUEL DELIVERY PIPE
a. Install new injector vibration insulators to the cylinder head.
b. Apply lubricant to the installation holes of the injectors.

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

NOTE:
- If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
- Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
- 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, No. 3) and a new E-ring to the fuel pipe as shown in the illustration.

NOTE:
- Check that there is no foreign matter or damaged areas in the fuel pipe O-ring groove.
- Check that the No. 1, No. 2 and No. 3 backup rings are installed in the correct direction.
- Make sure that 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. Press the fuel pipe and delivery pipe together by hand 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)

NOTE: Do not install the No. 3 fuel pipe at an angle.

6. INSTALL NO. 2 FUEL PIPE

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

NOTE:
- Check that there is no foreign matter or damaged areas in the fuel pipe O-ring groove.
- Check that the No. 1, No. 2 and No. 3 backup rings are installed in the correct direction.
- Make sure that 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 and connect the fuel pipe to the delivery pipe.

NOTE:
- Do not install the No. 2 fuel pipe at an angle.
- Do not install the bolts at this time.

7. INSTALL FUEL PUMP ASSEMBLY
8. CONNECT NO. 2 FUEL PIPE
9. INSTALL NO. 1 FUEL PIPE

a. Install the No. 1 fuel pipe with the 2 bolts.

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

b. Connect the 2 fuel hoses.

c. Connect the No. 3 fuel hose to the No. 1 fuel pipe.

10. INSTALL FUEL PRESSURE PULSATION DAMPER
11. CONNECT WATER HOSE JOINT

a. Connect the water hose joint with the bolt.

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

12. 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 4 connectors.

c. Push the fuel tube connector onto the delivery pipe and push up the retainer to engage the claws.

NOTE:
- Check for damage or foreign objects on the connected part.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

d. After connecting the fuel tube, align the paint marks on the delivery pipe.

13. INSTALL INTAKE AIR SURGE TANK
14. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
15. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
16. CONNECT NO. 2 VENTILATION HOSE
17. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
20. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
21. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
22. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH
23. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH
24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
25. ADD ENGINE COOLANT
26. INSPECT FOR COOLANT LEAK
27. INSPECT FOR FUEL LEAK
28. INSTALL V-BANK COVER SUB-ASSEMBLY
29. INSTALL ENGINE ROOM SIDE COVER LH
30. INSTALL ENGINE ROOM SIDE COVER RH
31. INSTALL COOL AIR INTAKE DUCT SEAL
32. CHECK FUNCTION OF THROTTLE BODY WITH MOTOR ASSEMBLY
33. PERFORM INITIALIZATION
a. Perform initialization

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