Fuel Injector (for Direct Injection)
REMOVAL1. PRECAUTION
CAUTION:
- Do not smoke or be near an open flame when working on the fuel system.
- Keep gasoline away from rubber or leather parts.
- 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.
2. DISCHARGE FUEL SYSTEM PRESSURE
a. 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.
NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
4. REMOVE INTAKE MANIFOLD
a. Remove the intake manifold.
5. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
a. Remove the fuel pressure pulsation damper assembly.
6. REMOVE NO.3 FUEL PIPE SUB-ASSEMBLY
7. REMOVE NO.2 FUEL PIPE SUB-ASSEMBLY
8. REMOVE ENGINE COVER SUB-ASSEMBLY
a. Remove the No.1, No.2 and LH No. 2 engine covers.
9. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY
a. Using SST, remove the fuel pipe.
SST 09023-12901
10. REMOVE VENTILATION HOSE
a. Remove the ventilation hose from the ventilation valve.
11. REMOVE NO. 2 FUEL DELIVERY PIPE
a. Disconnect the fuel pressure sensor connector.
b. Disconnect the 4 injector connectors.
c. Remove the 5 bolts and delivery pipe from the cylinder head.
NOTE:
- Make sure that the fuel delivery pipe is disconnected from the delivery pipe (RH side).
- Be extremely careful not to touch or strike the tips of the injectors.
- Pull and remove the fuel delivery pipe in a straight line without tilting it.
d. Remove the 4 injector vibration insulators from the cylinder head.
12. REMOVE FUEL DELIVERY PIPE
a. Disconnect the No. 3 fuel hose.
b. Disconnect the 4 injector connectors.
c. Remove the 5 bolts and delivery pipe from the cylinder head.
NOTE:
- Be extremely careful not to touch or strike the tips of the injectors.
- Pull and remove the fuel delivery pipe in a straight line without tilting it.
d. Remove the 4 injector vibration insulators from the cylinder head.
13. 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.
14. 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 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.
HINT: Check that the seal covers the circumference of the injector groove as given 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 seals are not scratched, deformed or protruding from the injector grooves.
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, backup rings (No. 1, No. 2 and No. 3) and 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.
b. Install the injector nozzle holder clamp.
1. 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. 2 FUEL DELIVERY PIPE
a. Install 4 new injector vibration insulators to the cylinder head.
b. Apply lubricant to the installation injector seal and holes of the injectors.
c. Install the delivery pipe (with injector) to the intake manifold with the 5 bolts.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
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 cylinder head.
- When inserting the fuel delivery pipe, push it in evenly without tilting it.
d. Connect the 4 connectors.
e. Connect the fuel pressure sensor connector.
4. INSTALL FUEL DELIVERY PIPE
a. Install 4 new injector vibration insulators to the cylinder head.
b. Apply lubricant to the installation injector seal and holes of the injectors.
c. Install the delivery pipe (with injector) to the intake manifold with the 5 bolts.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
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 cylinder head.
- When inserting the fuel delivery pipe, push it in evenly without tilting it.
d. Connect the 4 connectors.
e. Connect the No. 3 fuel hose.
5. INSTALL VENTILATION HOSE
a. Install the ventilation hose to the ventilation valve.
6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY
a. Temporarily install the fuel pipe.
b. Using SST, tighten the fuel pipe in the order shown in the illustration.
SST 09023-12901
Torque:
without SST
30 N.m (306 kgf.cm, 22 ft.lbf)
with SST
27 N.m (275 kgf.cm, 20 ft.lbf)
NOTE: After installing the fuel pipe, check that there is contiguous the fuel pipe protector and separator case.
HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.81 in).
- Make sure SST and wrench are connected in a straight line.
7. INSTALL ENGINE COVER SUB-ASSEMBLY
a. Install the No. 1, No. 2 and LH No. 2 engine covers.
8. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY
a. Install a new O-ring, backup rings (No. 1 and No. 2) and 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.
b. Temporarily install the No.3 fuel pipe to the delivery pipe with the 2 bolts.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
c. Temporarily install the No.3 fuel pipe sub-assembly to the fuel pump.
NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
d. Install the No. 3 fuel pipe to the delivery pipe with the 2 bolts and tighten them in several passes.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
e. Using SST, tighten the union nut.
SST 09023-12901
Torque:
without SST
30 N.m (306 kgf.cm, 22 ft.lbf)
with SST
27 N.m (275 kgf.cm, 20 ft.lbf)
NOTE: There must be absolutely no free play in the union on the fuel pump side. If the union on the fuel pump side has free play, replace the fuel pump.
HINT:
- Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
- Make sure SST and wrench are connected in a straight line.
f. Connect the connector to the fuel pump.
9. INSTALL NO.2 FUEL PIPE SUB-ASSEMBLY
HINT: The installation procedures are the same as the No. 3 fuel pipe sub-assembly.
10. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
a. Install the fuel pressure pulsation damper assembly.
11. INSTALL INTAKE MANIFOLD
a. Install the intake manifold.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable to the negative (-) battery terminal.
14. ADD ENGINE COOLANT
15. CHECK FOR COOLANT LEAKS
16. CHECK FOR FUEL LEAKS