Fuel Injector: Service and Repair
Fuel Injector Assy Part 1:
Fuel Injector Assy Part 2:
FUEL INJECTOR ASSEMBLY
REPLACEMENT
NOTE: When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.
- Power window control system
- Sliding roof system
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE ENGINE COVER SUB-ASSEMBLY NO.1
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
5. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Remove the fuel tube from the fuel hose clamp.
b. Remove the fuel pipe clamp No. 2.
c. Using SST, disconnect the fuel tube from the fuel delivery pipe.
SST 09268-21010
1. Hold the fuel tube connector in your hand, then install SST.
2. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST. Insert SST into the fuel tube connector.
3. Hold SST in the position above, then push the fuel tube connector towards SST. Mount the retainer of the fuel tube connector onto the chamfered part of SST.
HINT: The retainer of the fuel tube connector is unlocked.
4. Slide SST and fuel tube connector together to the fuel tube side until they make a "click" sound, then disconnect the fuel tube.
NOTE:
- Remove any dirt and foreign objects on the connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the connector has the O-ring that seals the pipe.
- Perform this work with SST. Do not use any other tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
d. Disconnect the ventilation hose No. 2 from the ventilation valve.
e. Remove the 2 wire harness clamps.
f. Disconnect the 4 fuel injector connectors.
g. Remove the 2 bolts, then remove the fuel delivery pipe together with the 4 fuel injectors.
NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
h. Remove the 2 delivery pipe No. 1 spacers from the cylinder head.
i. Remove the 4 insulators from the cylinder head.
6. REMOVE FUEL INJECTOR ASSEMBLY
a. Pull the 4 fuel injectors out of the fuel delivery pipe.
7. INSTALL FUEL INJECTOR ASSEMBLY
a. Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each fuel injector.
b. Apply a light coat of gasoline or spindle oil to the fuel delivery pipe which comes into contact with the O-ring of the fuel injector.
c. Apply a light coat of gasoline or spindle oil to the O-ring again, then install the fuel injector right and left onto the fuel delivery pipe.
NOTE: Make sure that the O-ring is not cracked or jammed when installing.
d. Check that the fuel injector rotate smoothly.
If the fuel injector does not rotate, replace the O-ring.
8. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Install 4 new insulators into the cylinder head.
b. Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
c. Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 2 bolts.
NOTE: Do not drop the 4 fuel injectors when installing the fuel delivery pipe.
d. Check that the fuel injector rotate smoothly.
If the fuel injector does not rotate, replace the O-ring.
e. Retighten the 2 bolts to specified torque.
Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
f. Connect the 4 fuel injector connectors.
g. Install the 2 wire harness clamps.
h. Connect the ventilation hose No. 2 to the ventilation valve.
NOTE: Make sure that the paint mark and hose clamp are at the correct angle when installing.
i. Align the connector with the pipe, then push the connector into the pipe until it makes a "click" sound to connect the fuel tube to the fuel delivery pipe.
NOTE:
- Check if there is any damage or foreign objects on the connected parts.
- After connecting, check that the connector and pipe are securely connected by pulling them.
j. Install the fuel pipe clamp No. 2.
k. Install the fuel tube into the fuel hose clamp.
9. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
10. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
11. CHECK FOR FUEL LEAKAGE
12. INSTALL ENGINE COVER SUB-ASSEMBLY NO.1