Removal And Installation

FUEL INJECTOR AND FUEL TUBE

Removal and Installation


WARNING:
- Be sure to read Precaution For Handling High Pressure Fuel System when working on the high pressure fuel system.
- Put a "CAUTION: FLAMMABLE" sign in the workshop.
- Be sure to work in a well ventilated area and furnish workshop with a fire extinguisher.
- Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
- To avoid the danger of being scalded, never drain engine coolant when engine is hot.

REMOVAL

1.Release the fuel pressure. Testing and Inspection.
2.Remove front bumper. Exploded View
3.Remove charge air cooler. Exploded View.
4.Remove oil level gauge. Exploded View.
5.Remove intake manifold. Exploded View.
6.Remove alternator. Exploded View
7.Remove oil level gauge guide. Exploded View.
8.Remove fuel rail cover, and then remove fuel rail insulator.

CAUTION:
When fuel rail insulator (separated type) and adapter cover (separated type) are removed, be sure to replace them with fuel rail insulator (united type).
9.Remove fuel tube and fuel rail connector. Exploded View.
10.Disconnect fuel pressure sensor harness connector.
11.Disconnect fuel injector harness connector.
12.Remove fuel pressure sensor, if necessary.
13.Remove fuel rail.





- Loosen mounting bolts in reverse order as shown in the figure.

White arrow indicates : Engine front

CAUTION:
- When removing, be careful to avoid any interference with fuel injector.
- Use a shop cloth to absorb any fuel leakage from fuel rail.
14.Remove fuel injector from cylinder head as per the following.

CAUTION:
- Be careful with remaining fuel that may go out from fuel rail.
- Be careful not to damage injector nozzles during removal.
- Never bump or drop fuel injector.
- Never disassemble fuel injector.
a.Remove injector holder.





b.Install an remover [SST: KV-10119600 (-)] (A) to the injector connector side so that cutout (B) of injector remover faces the injector connector side.





- Hook pawl portion (B) of injector remover [SST: KV-10119600
(-)] (A) to groove portion (C) of injector c.Press down body portion of injector remover [SST: KV-10119600 (-)] (A) until it contacts cylinder head.










d.Tighten injector remover [SST: KV-10119600 (-)] clockwise and remove injector from cylinder head.





e.Cut seal ring (1) while pinching it. Be careful not to damage injector.

INSTALLATION


CAUTION:
Do not reuse O-rings.
1.Install seal ring to fuel injector as per the following:

CAUTION:
- Handle seal ring with bare hands. Never wear gloves.
- Never apply engine oil to seal ring.
- Never clean seal ring with solvent.





a.Install an injector seal drift set [SST: KV-101197S0 (-)] (A) to fuel injector (1).





b.Set seal ring (1) to injector seal drift set [SST: KV-101197S0 (-)]
(A).





c.Straightly insert seal ring (1), which is set in step 2, to fuel injector as shown in the figure and install.

CAUTION:
Be careful that seal ring does not exceed the groove portion of fuel injector.





d.Insert injector seal drift set [SST: KV-101197S0 (-)] (A) to injector and rotate clockwise and counterclockwise by 90�
while pressing seal ring to fit it.
NOTE:
Compress seal ring, because this operation is for rectifying stretch of seal ring caused by installation and for preventing sticking when inserting injector into cylinder head.
2.Install O-ring and backup ring to fuel injector. When handing new O-ring and backup ring, paying attention to the following caution items:

CAUTION:
- Do not reuse O-ring.
- Handle O-ring with bare hands. Never wear gloves.
- Lubricate O-ring with new engine oil.
- Never clean O-ring with solvent.
- Check that O-ring and its mating part are free of foreign material.
- When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube.
- Insert new O-ring straight into fuel rail. Never decenter or twist it.





- Always install the back up ring (1) in the right direction as instructed.





3.Install fuel injector (1) to fuel rail (2) as per the following:





a.Install fuel injector holder (5) to fuel injector.

CAUTION:
- Never reuse fuel injector holder. Replace it with a new one.
- Be careful to keep fuel injector holder from interfering with O-ring. If interference occurs, replace O-ring.
b.Insert fuel injector into fuel rail with fuel injector holder attached.
- Insert it while matching it to the axial center.
- Insert so that protrusion (A) of fuel injector is aligned to cutout (B).
c.Check that installation is complete by checking that fuel injector does not rotate or come off.
- Check that protrusions of fuel injectors and fuel rail are aligned with cutouts of clips after installation.
4.Install fuel rail and fuel injector assembly to cylinder head.





- Tighten mounting bolts and nuts in two steps in numerical order as shown in the figure.

White arrow indicates : Engine front

1st step: 10.0 Nm (1.0 kg-m, 89 in-lb)
2nd step: 20.5 Nm (2.1 kg-m, 15 ft-lb)

5.Connect injector harness connector.
6.Install fuel pressure sensor, if removed.
7.Install fuel rail insulator.

CAUTION:
- As covering part of fuel tube connector at the back end of common rail can easily move because of its shape, do not remove it before installation.
- Install the insulator so that it is placed under lower side of intake manifold flange.
8.Install in the reverse order of removal after this step.