Removal And Installation

FUEL INJECTOR AND FUEL TUBE

Removal and Installation


WARNING:
- Put a "CAUTION: FLAMMABLE" sign in the workshop.
- Be sure to work in a well ventilated area and furnish workshop with a CO-2 fire extinguisher.
- Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.

CAUTION:
- Apply new engine oil to parts before installing the parts, as shown above.
- Do not remove or disassemble parts unless instructed as shown.

REMOVAL

1.Release the fuel pressure. Fuel Pressure Check For California (for California) or Fuel Pressure Check Except For California (except for California).
2.Disconnect the battery negative terminal. Removal and Replacement.





3.Remove quick connector cap (1) from quick connector connection.





4.Disconnect fuel feed hose from hose clamp.





NOTE:
There is no fuel return path.
5.With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.





6.Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position.

CAUTION:
Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.
7.Draw and pull out quick connector straight from fuel tube.

CAUTION:
- Pull quick connector holding "A" position.
- Do not reuse O-ring.
- Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
- Prepare container and cloth beforehand as fuel will leak out.
- Avoid fire and sparks.
- Keep parts away from heat source. Especially, be careful when welding is performed around them.
- Do not expose parts to battery electrolyte or other acids.
- Do not bend or twist connection between quick connector and fuel feed hose during installation/
removal.





- To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
8.Remove intake manifold.





9.Remove fuel tube.
- Loosen bolts in reverse order as shown.





10.Remove the fuel tube and fuel injector assembly.

CAUTION:
- When removing, be careful to avoid any interference with fuel injector.
- Use a shop cloth to absorb any fuel leaks from fuel tube.
11.Remove fuel injector from fuel tube with the following procedure:
a.Open and remove clip.
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 fuel injector nozzle during removal.
- Never bump or drop fuel injector.
- Never disassemble fuel injector.

INSTALLATION

1.Install new O-rings on the fuel injector.
- Fuel tube side: Black
- Nozzle side: Green

CAUTION:
- Do not reuse O-rings.
- Upper and lower O-rings are different. Be careful to install them in the correct location.
- Handle O-ring with bare hands. Never wear gloves.
- Lubricate O-ring with new engine oil.
- Never clean O-ring with solvent.
- Make sure that O-ring and its mating part are free of foreign material.
- When installing O-ring, be careful not to scratch or nick it.
- Also be careful not to twist or stretch O-ring. If O-ring was stretched, allow it time to return to an unstretched condition prior to installation.
- Insert O-ring straight into fuel tube. Never twist it.
- Never insert the O-ring quickly into fuel tube.





2.Install fuel injector (4) to fuel tube (1) with the following procedure:





a.Insert clip (2) into clip groove (F) on fuel injector.
- Insert clip so that protrusion (G) of fuel injector matches cutout (D) of clip.

CAUTION:
- Do not reuse O-rings.
- Never reuse clip. Replace it with a new one.
- Be careful to keep clip from interfering with O-ring.
- If interference occurs during installation replace the Oring.
b.Insert fuel injector into fuel tube with clip attached.
- Insert it while matching it to the axial center.
- Insert fuel injector so that protrusion (B) of fuel tube matches cut-out (C) of clip.
- Make sure that fuel tube flange (A) is securely fixed in flange fixing groove (E) on clip.
c.Make sure that installation is complete by making sure that fuel injector does not rotate or come off.
3.Set fuel tube and fuel injector assembly at its position for installation on cylinder head.

CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.





4.Tighten bolts in numerical order as shown.





5.Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION

Make sure there is no fuel leakage at connections as follows:
1.Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
2.Start the engine and rev it up and check for fuel leaks at connections.

CAUTION:
Do not touch engine immediately after stopping as engine is extremely hot.
NOTE:
Use mirrors for checking on connections out of the direct line of sight.
- Perform procedures for "Throttle Valve Closed Position Learning" after finishing repairs. For California "Throttle Valve Closed
Position Learning" (for California).
- If electric throttle control actuator is replaced, perform procedures for "Idle Air Volume Learning" after finishing repairs. For California (except for California) or "Idle Air
Volume Learning" (for California).