Fuel Injector: Service and Repair

INJECTORS REMOVAL
1. REMOVE AIR CLEANER HOSE
2. REMOVE AIR INTAKE CHAMBER ASSEMBLY



3. DISCONNECT INJECTOR CONNECTORS
4. REMOVE AIR ASSIST HOSES AND PIPE



- Disconnect the air assist pipe from the bracket on the No.1 fuel pipe.
- Remove the air assist hoses from the intake manifold.

5. DISCONNECT FUEL INLET AND RETURN HOSES
- Disconnect the fuel return hose from the No.1 fuel pipe.



- Disconnect the fuel inlet hose from the fuel filter.

CAUTION: Catch leaking fuel in a container.

6. REMOVE DELIVERY PIPES AND INJECTORS

NOTICE: Be careful not to drop the injectors when removing the delivery pipes.




- Loosen the 2 union bolts holding the No.2 fuel pipe to the delivery pipes.
- Disconnect the fuel return hose from the fuel pressure regulator.
- Remove the union bolt for the RH delivery pipe, 2 gaskets, 2 bolts and LH delivery pipe together with the 3 injectors and No.2 fuel pipe.
- Remove the union bolt for the LH delivery pipe and 2 gaskets from the No.2 fuel pipe.



- Remove the 3 bolts, RH delivery pipe together with the 3 injectors and No.1 fuel pipe.
- Remove the 4 spacers from the intake manifold.
- Pull out the 6 injectors from the delivery pipes.
- Remove the 2 O-rings and 2 grommets from each injector.


INJECTORS INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES



- Install 2 new insulator and grommet to each injector.
- Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector.



- While turning the injector clockwise and counter-clockwise, push it to the delivery pipes. Install the 6 injectors.
- Position the injector connector outward.




- Place the 4 spacers in position on the intake manifold.



- Place the RH delivery pipe and No.1 fuel pipe together with the 3 injectors in position on the intake manifold.
- Temporarily install the 2 bolts holding the RH delivery pipe to the intake manifold.
- Temporarily install the bolt holding the No.1 fuel pipe to the intake manifold.




- Place the LH delivery pipe and No.2 fuel pipe together with the 3 injectors in position on the intake manifold.
- Connect the fuel return hose to the fuel pressure regulator.
- Temporarily install the 2 bolts holding the LH delivery pipe to the intake manifold.
- Temporarily install the No.2 fuel pipe to the LH delivery pipe with the union bolt and 2 new gaskets.



- Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.
- Position the injector connector outward.




- Tighten the 4 bolts holding the delivery pipes to the intake manifold.
Torque: 10 Nm (7 ft.lb)
- Tighten the bolt holding the No.1 fuel pipe to the intake manifold.
Torque: 19.5 Nm (14 ft.lb)
- Tighten the 2 union bolts holding the No.2 fuel pipe to the delivery pipes.
Torque: 32.5 Nm (24 ft.lb)

2. CONNECT FUEL INLET AND RETURN HOSES



- Connect the fuel inlet hose to the fuel filter with the 2 new gaskets and union bolt.
Torque: 29 Nm (21 ft.lb)
- Connect the fuel return hose to the No.1 fuel pipe.
HINT: Pass the fuel return hose under the heater hoses.

3. INSTALL AIR ASSIST HOSES AND PIPE



- Connect the air assist hoses to the intake manifold.
- Install the air assist pipe to the bracket on the No.1 fuel pipe.

4. CONNECT INJECTOR CONNECTORS
5. INSTALL AIR INTAKE CHAMBER ASSEMBLY
6. INSTALL AIR CLEANER HOSE