Fuel Injector: Service and Repair
Fuel Injector Assy Components:
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 4 nuts and cylinder head cover.
3. REMOVE IGNITION COIL NO.1
a. Disconnect the 4 ignition coil connectors.
b. Remove the 4 bolts and 4 ignition coils.
4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Disconnect the ventilation hose No. 2.
b. Disconnect the ventilation hose.
c. Remove the 9 bolts, 2 nuts, 2 seal washers and then remove the cylinder head cover.
5. DISCONNECT FUEL TUBE SUB-ASSEMBLY
a. Remove the fuel pipe clamp.
b. Using SST, disconnect the fuel tube.
SST 09268-21010
1. Assemble SST to the connection of the fuel tube as shown in the illustration.
2. Turn SST, align the retainers inside the connector with SST chamfered parts and insert the SST into the connector.
3. Push in SST and the connector together towards the fuel tube assembly.
NOTE:
- Check the pipe and around the connector for dirt or mud before disconnecting them and remove the dirt as necessary.
- Do not bent and twist the nylon tube.
- When the connector and pipe are stuck, push and pull the connector to release and disconnect and pull it out.
- Prevent the disconnected pipe and connector from being damaged and foreign objects being introduced by covering them with a vinyl or plastic bag.
6. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Disconnect the 4 fuel injector connectors.
b. Remove the 3 bolts and then remove the fuel delivery pipe with the 4 fuel injectors.
NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
c. Remove the 2 spacers from the cylinder head.
7. REMOVE FUEL INJECTOR ASSEMBLY
a. Pull out the 4 fuel injectors.
8. INSTALL FUEL INJECTOR ASSEMBLY
a. Install new insulators to each fuel injector.
b. Apply a light coat of grease or gasoline to new O-rings and install them to each fuel injector.
c. Apply a light coat of grease or gasoline on the place where a fuel delivery pipe contacts the O-ring.
d. While turning the fuel injector clockwise and counterclockwise, push it to the fuel delivery pipe.
NOTE:
- Be careful not to twist the O-ring.
- After installing the fuel injectors, check that they turn smoothly. If not, replace it with a new O-ring.
9. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Install the 2 spacers to the cylinder head.
b. Install the fuel delivery pipe and 4 fuel injectors together.
Torque:
19 N.m (194 kgf.cm, 14 ft.lbf) for bolt A
9.0 N.m (92 kgf.cm, 80 in.lbf) for bolt B
NOTE:
- Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
- Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.
c. Connect the 4 fuel injector connectors.
10. CONNECT FUEL TUBE SUB-ASSEMBLY
a. Connect the fuel tube.
NOTE:
- Check the connected parts of the pipe for damage or foreign objects.
- After finishing the connection, check if the pipe and connector are securely connected by pulling on them.
b. Install the fuel pipe clamp.
11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Apply seal packing to the 2 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent
NOTE:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes after applying seal packing.
- Do not start engine within 2 hours of installation.
b. Install the cylinder head cover with the 9 bolts, 2 nuts and 2 seal washers.
c. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf.cm, 7 ft.lbf)
d. Connect the ventilation hose.
e. Connect the ventilation hose No. 2.
12. INSTALL IGNITION COIL NO.1
Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
13. CHECK FOR FUEL LEAKS
14. INSTALL CYLINDER HEAD COVER NO.2
a. Install the cylinder head cover.
b. First tighten nut A, then tighten nut B.
Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)