Fuel Injector: Service and Repair

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

CAUTION:
- The "DISCHARGE FUEL SYSTEM PRESSURE" procedures must be performed before disconnecting any part of the fuel system.
- After performing the "DISCHARGE FUEL SYSTEM PRESSURE" procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray.

a. Remove the rear seat cushion assembly.
b. Remove the rear floor No. 2 service hole cover.

c. Disconnect the connector.
d. Start the engine. After the engine has stopped, turn the ignition switch OFF.

HINT: DTC P0171, P0174 (system too lean) may be set.

e. Check that the engine does not start.
f. Remove the fuel tank cap, and let the air out of the fuel tank.

g. Connect the connector.
h. Install the rear floor No. 2 service hole cover.
i. Install the rear seat cushion assembly.

2. 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.

3. DRAIN ENGINE COOLANT

4. REMOVE V-BANK COVER
a. Remove the 2 nuts and cover.

5. REMOVE NO. 1 AIR CLEANER INLET
a. Remove the bolt and air cleaner inlet.

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

7. REMOVE NO. 1 V-BANK COVER BRACKET
a. Remove the bolt and bracket.

8. REMOVE NO. 2 V-BANK COVER BRACKET
a. Remove the nut and bracket.

9. REMOVE NO. 3 V-BANK COVER BRACKET
a. Remove the bolt and bracket.

10. REMOVE NO. 4 V-BANK COVER BRACKET
a. Remove the 2 nuts and bracket.

11. REMOVE PURGE VSV

12. DISCONNECT ENGINE WIRE

a. Disconnect the 2 wire clamp from the wire clamp bracket on the RH delivery pipe.

13. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

14. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Disconnect the connectors.

b. Remove the 2 nuts and fuel delivery pipe.

NOTE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.

c. Remove the 2 spacers from the intake manifold.

15. REMOVE NO. 2 DELIVERY PIPE SUB-ASSEMBLY
a. Disconnect the connectors.

a. Remove the 8 fuel injectors from the intake manifold.

NOTE:
- When removing an injector, do not apply force in a lateral direction.
- For reinstallation purposes, attach a tag or label to the injector shaft.

b. Remove the O-ring, grommet and insulator.

INSTALLATION

1. INSTALL FUEL INJECTOR ASSEMBLY

a. Install a new O-ring, grommet and insulator to the injector.

NOTE:
- Check that there is no damage or foreign material in the groove of the injector when installing the injector's O-ring.
- Apply gasoline to a new O-ring and install it to the injector.

b. Push and rotate the injector 45° clockwise and counterclockwise to install it to the delivery pipe.
c. Check that the injector rotates smoothly.

NOTE: When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.

2. INSTALL NO. 2 FUEL DELIVERY PIPE SUBASSEMBLY

a. Install the delivery pipe (with injector) to the intake manifold.

b. With the condition as stated above, rotate the injector 45° clockwise and counterclockwise.

NOTE: When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.

c. With the spacer contacting the delivery pipe, install the delivery pipe with the 2 nuts.

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

3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

a. Install the delivery pipe (with injector) to the intake manifold.

a. Install the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.

6. INSTALL PURGE VSV

7. INSTALL NO. 4 V-BANK COVER BRACKET
a. Install the bracket with the 2 nuts.

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

8. INSTALL NO. 3 V-BANK COVER BRACKET
a. Install the bracket with the bolt.

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

9. INSTALL NO. 2 V-BANK COVER BRACKET
a. Install the bracket with the nut.

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

10. INSTALL NO. 1 V-BANK COVER BRACKET
a. Install the bracket with the bolt.

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

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

Torque:
4.0 N.m(41 kgf.cm, 35 in.lbf) for hose clamp
5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt

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

12. INSTALL NO. 1 AIR CLEANER INLET
a. Install the air cleaner inlet with the bolt.

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

13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

14. PERFORM INITIALIZATION
a. Perform initialization.

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

15. CHECK FOR FUEL LEAKS
16. ADD COOLANT
17. CHECK FOR COOLANT LEAKS

18. INSTALL V-BANK COVER
a. Install the cover with the nuts.

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