Fuel Injector: Service and Repair

FUEL INJECTOR AND FUEL TUBE:

Removal and Installation

CAUTION: Apply new engine oil when installing the parts that specified to do so in the figure.
Do not remove or disassembly parts unless instructed as shown in the figure.

REMOVAL
1. Release fuel pressure.
2. Remove intake manifold upper with power tool.
3. Disconnect injector harness connectors.
4. Disconnect vacuum hoses from fuel pressure regulator and fuel damper.
5. Disconnect fuel hoses from fuel tube assembly.
6. Disconnect fuel sub tube from fuel tube RH and LH.
7. Remove injectors with fuel tube assembly.






8. Expand and remove clips securing fuel injectors.
9. Extract fuel injectors straight from fuel tubes.
Be careful not to damage injector nozzles during removal.
Do not bump or drop fuel injectors.


INSTALLATION
1. Carefully install 0-rings, including the one used with the pressure regulator.
- Lubricate O-rings by smearing new engine oil.
- Be careful not to damage O-rings and surfaces for O-ring sealing with service tools, finger nails or clips. Do not expand or twist O-rings.
- Discard old clips; replace with new ones.

2. Position clips in grooves on fuel injectors.
Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.

3. Align protrusions of fuel tubes with those of fuel injectors.
4. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with those of fuel injectors, and that flanges of fuel tubes are engaged with clips.

FUEL TUBE MOUNTING BOLTS:

5. Tighten fuel tube assembly mounting bolts "a" to "c" in illustration and in two steps.

1st Step:..........9.3 - 10.8 Nm (0.95 - 1.1 kg-m, 6.2 - 7.9 ft. lbs.)
2nd Step:..........20.6 - 26.5 Nm (2.1 - 2.7 kg-m, 16 - 19 ft. lbs.)

6. Install all removed parts in the reverse order of removal.

CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.

INSPECTION AFTER INSTALLATION
Check on Fuel Leakage

1. Start the engine, and run it for a few minutes with engine at idle.
2. Stop the engine, and check for fuel leakage both visually and by odor of gasoline.

NOTE: Use mirrors for checking on invisible points.

CAUTION: Do not touch the engine immediately after stopped, as engine becomes extremely hot.