Removal and Installation

FUEL INJECTOR AND FUEL TUBE

Removal and Installation


REMOVAL


WARNING:
- Put a "CAUTION: FLAMMABLE" sign in the workshop.
- Be sure to work in a well ventilated area and furnish workshop with a CO2fire extinguisher.
- Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
- Never drain engine coolant when the engine is hot to avoid the danger of being scalded.
1.Release fuel pressure. Refer to "Inspection" Testing and Inspection.
2.Disconnect battery cable from the negative terminal. Refer to "Exploded View" Exploded View.
3.Remove engine cover with power tool. Refer to "Exploded View" Exploded View.
4.Remove air cleaner case and air duct (RH and LH). Refer to "Exploded View" Exploded View.
5.Remove intake manifold collector. Refer to "Exploded View" Exploded View.





6.Remove fuel feed hose (with damper) (1) from fuel sub-tube (2)
and remove harness bracket (3).





NOTE:
There is no fuel return route.

CAUTION:
- While hoses are disconnected, plug them to prevent fuel from draining.
- Never separate damper and hose.
7.When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows:





a.Remove quick connector cap (2) from quick connector connection on right member side.
b.Disconnect fuel feed hose (with damper) (1) from bracket hose clamp.





c.Push in retainer tabs (2).
d.Draw and pull out quick connector (1) straight from centralized under-floor piping (3).

CAUTION:
- Pull quick connector holding (A) position as shown in the figure.
- Never pull with lateral force applied. O-ring inside quick connector may be damaged.
- Prepare container and cloth beforehand because fuel will leakage out.
- Avoid fire and sparks.
- Keep parts away from heat source. Especially, be careful when welding is performed around them.
- Never expose parts to battery electrolyte or other acids.
- Never bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal.





- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or a similar item.
8.Remove fuel sub tube mounting bolt.
9.Disconnect harness connector from fuel injector.





10.Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly.






CAUTION:
Never tilt it, or remaining fuel in pipes may flow out from pipes.





11.Remove fuel injector (2) from fuel tube (4) as follows:





a.Open and remove clip (1).
b.Remove fuel injector from fuel tube by pulling straight.

CAUTION:
- Be careful with remaining fuel that may go out from fuel tube.
- Be careful not to damage injector nozzles during removal.
- Never bump or drop fuel injector.
- Never disassemble fuel injector.
12.Remove fuel sub-tube and fuel damper, if necessary.

INSTALLATION


CAUTION:
Do not reuse O-rings.





1.Install fuel damper (4) as follows:





a.Install new O-ring (1) to fuel tube as shown. When handling new
O-ring, pay 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 tube. Never twist it.
b.Install spacer (3) to fuel damper.
c.Insert fuel damper straight into fuel tube.

CAUTION:
- Insert straight, checking that the axis is lined up.
- Never pressure-fit with excessive force.

Reference value: 130 N (13.3 kg, 29.2 lb)

- Insert fuel damper until (A) is touching (B) of fuel tube.





d.Install the cut-out (A) of the clip (2) to the projection (B), which ensures that the fuel tube does not move or rotate.





e.Unlock the clip after checking that the rib of the cup and the brim of the fuel damper are mated each other and positioned in the holes (C) of the clip.





f.Check that the opening (B) and the slit (C) of the clip are positioned and fixed properly so it does not rotate or pull out.





2.Install fuel sub-tube.
- When handling new O-rings, be careful of the following caution items:

CAUTION:
- Do not reuse O-rings.
- 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 tube. Never decenter or twist it.
- Insert fuel sub-tube straight into fuel tube.
- Tighten mounting bolts evenly in turn.
- After tightening mounting bolts, Check that there is no gap between flange and fuel tube.
3.Install new O-rings to fuel injector, paying attention to the following items.

CAUTION:
- Do not reuse O-rings.
- Upper and lower O-ring are different. Be careful not to confuse them.

Fuel tube side: Black
Nozzle side: Green

- 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 O-ring straight into fuel injector. Never decenter or twist it.





4.Install fuel injector to fuel tube as follows:





a.Insert clip (3) into clip mounting groove (F) on fuel injector (5).

CAUTION:
- Never reuse clip. Replace it with a new one.
- Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.
- Insert clip so that protrusion (E) of fuel injector matches cut-out (C) of clip.
b.Insert fuel injector into fuel tube (1) with clip attached.
- Insert it while matching it to the axial center.
- Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip.
- Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip.
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 tube are aligned with cutouts of clips after installation.
5.Install fuel tube and fuel injector assembly to intake manifold.

CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.





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









6.Connect injector sub-harness.
7.Install fuel sub tube mounting bolt.
8.Connect fuel feed hose (with damper).
- Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube.
- Insert fuel damper straight into fuel sub-tube.
- Tighten mounting bolts evenly in turn.
- After tightening mounting bolts, check that there is no gap between flange and fuel sub-tube.
9.Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping connection as follows:
a.Check that no foreign substances are deposited in and around centralized under-floor piping and quick connector, and that there is no damage to them.
b.Thinly apply new engine oil around centralized under-floor piping from tip end to spool end.
c.Align center to insert quick connector straightly into centralized under-floor piping.
- Insert quick connector to centralized under-floor piping until top spool is completely inside quick connector and 2nd level spool exposes right below quick connector.

CAUTION:
- Hold align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
- Insert until you hear a "click" sound and actually feel the engagement.
- To avoid mis-identification of engagement with a similar sound, be sure to perform the next step.





d.Pull quick connector by hand holding position (A). Check it is completely engaged (connected) so that it does not come out from centralized under-floor piping (1).





e.Install quick connector cap (3) to quick connector connection.





- Install quick connector cap with arrow (A) on surface facing in direction of quick connector (fuel feed hose side).

CAUTION:
If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check the connection again.
10.Install in the reverse order of removal after this step.