Fuel Injector: Service and Repair

REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL
2. REMOVE ENGINE ROOM SIDE COVER LH
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE FRONT UPPER FENDER PROTECTOR LH
6. REMOVE FRONT UPPER FENDER PROTECTOR RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH
8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
13. DISCHARGE FUEL SYSTEM PRESSURE
14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
15. DRAIN ENGINE COOLANT
16. DISCONNECT NO. 2 VENTILATION HOSE
17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
18. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

19. SEPARATE COLD START INJECTOR

a. Disconnect the cold start injector connector.
b. Separate the 2 bolts and cold start injector.

20. REMOVE INTAKE AIR SURGE TANK

a. Disconnect the vacuum hose from the intake air surge tank.
b. Remove the bolt and disconnect the purge VSV from the intake air surge tank.

c. Disconnect the wire harness and hose from the surge tank.

d. Disconnect the ventilation hose from the intake air surge tank.

e. Remove the bolt and water hose joint from the intake air surge tank.

f. Remove the bolt and disconnect the surge tank stay.

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

21. REMOVE INTAKE MANIFOLD
a. Disconnect the connector for the SCV.
b. Disconnect the SCV position sensor connector.

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

22. DISCONNECT WATER HOSE JOINT

a. Remove the bolt and water hose joint.

23. REMOVE FUEL PRESSURE PULSATION DAMPER

a. Using SST, remove the fuel pressure pulsation damper from the fuel pump.

24. 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.

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

27. 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.

28. 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.

29. 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.

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

31. REMOVE FUEL INJECTOR

a. Secure the delivery pipe in a vise between aluminum plates 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 clamps from the injectors.
c. Remove the O-ring, backup rings and E-ring from the fuel injector.

32. 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.
- 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 injector 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 given 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 given 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 given in the illustration.

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

g. Check that the seal covers the circumference of the injector groove as given 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 given 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 given 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 in 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 given 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 in 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 the seal is 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 given 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 and No. 2 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 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 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 given 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 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 screw 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) and new E-ring to the fuel injector as given 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 and No. 2 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 and No. 2) and new E-ring to the fuel injector as given 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 and No. 2 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 given 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 No.2 fuel pipe at an angle.
- Do not install the bolt at this time.

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

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 2 fuel hoses.

10. INSTALL FUEL PRESSURE PULSATION DAMPER

a. Using SST, install a new gasket and the fuel pulsation damper to the fuel pump.

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

HINT: The torque shown should be used for tightening without using SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST.

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

13. INSTALL INTAKE AIR SURGE TANK

a. Install a new gasket to the intake air surge tank.
b. Using a 5 mm hexagon socket wrench, install the 6 bolts.

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

c. Install the bolt and 2 nuts to the intake air surge tank.

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

d. Install the surge tank stay to the intake air surge tank.

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

e. Connect the water hose joint with the bolt.

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

f. Connect the ventilation hose to the intake air surge tank.

g. Connect the wire harness and hose to the intake air surge tank.

h. Connect the purge VSV to the intake air surge tank.

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

i. Connect the vacuum hose to the intake air surge tank.

14. INSTALL COLD START INJECTOR

a. Connect the cold start injector with the 2 bolts.

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

b. Connect the cold cold start injector connector.

15. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY
16. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
17. CONNECT NO. 2 VENTILATION HOSE
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
19. ADD ENGINE COOLANT
20. CHECK FOR COOLANT LEAKAGE
21. CHECK FOR FUEL LEAKAGE
22. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
23. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
24. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
25. INSTALL FRONT WIPER ARM HEAD CAP
26. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
27. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
28. INSTALL FRONT UPPER FENDER PROTECTOR LH
29. INSTALL FRONT UPPER FENDER PROTECTOR RH

HINT: Installation procedure of the RH side is the same as that of the LH side.

30. INSTALL V-BANK COVER SUB-ASSEMBLY
31. INSTALL ENGINE ROOM SIDE COVER LH
32. INSTALL ENGINE ROOM SIDE COVER RH
33. INSTALL COOL AIR INTAKE DUCT SEAL
34. CHECK FUNCTION OF THROTTLE WITH MOTOR BODY ASSEMBLY

35. PERFORM INITIALIZATION
a. Perform initialization.

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