Fuel Injector: Service and Repair
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 CO2 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. Testing and Inspection.
2. Remove the cowl top. Service and Repair.
3. Remove the front air duct and electric throttle control actuator tube and resonator. Service and Repair, "Removal and Installation".
4. Remove the battery tray. Removal And Installation.
5. Remove the engine room cover.
6. Remove the air cleaner assembly. Service and Repair.
7. Disconnect the fuel hose quick connector at the fuel tube side. Service and Repair.
CAUTION:
- Prepare a container and shop cloth for catching any spilled fuel.
- While hoses are disconnected seal their openings with vinyl bag or similar material to prevent foreign material from entering them.
8. Remove the intake manifold. Service and Repair.
9. Disconnect sub-harness for injector at engine front side, and remove it from bracket.
10. Loosen the bolts in the order as shown, then remove fuel tube and fuel injectors as an assembly.
11. Remove the fuel injectors from the fuel tube.
- Release the clip and remove the fuel injector.
- Pull fuel injector straight out of the fuel tube.
CAUTION:
- Be careful not to damage the nozzle.
- Avoid any impact, such as dropping the fuel injector.
- Do not disassemble or adjust the fuel injector.
INSTALLATION
1. Install new O-rings on the fuel injector.
- Fuel tube side: Black
- Nozzle side: Green
CAUTION:
- 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 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 tube. Never twist it.
2. Install the fuel injector into the fuel tube with the following procedure:
- Do not reuse the clip, replace it with a new one.
- Insert the new clip into the clip attachment groove on fuel injector.
- Insert the clip so that lug "A" of fuel injector matches notch "A" of the clip.
3. Insert fuel injector into fuel tube with clip attached.
- Insert it while matching it to the axial center.
- Insert fuel injector so that lug "B" of fuel injector matches notch "B" of the clip.
- Make sure that fuel tube flange is securely fixed in flange fixing groove on the clip.
- Make sure that installation is complete by checking that fuel injector does not rotate or come off.
4. Install fuel tube assembly.
a. Insert the tip of each fuel injector into intake manifold.
b. Tighten the bolts in two steps in the numerical order as shown.
CAUTION:
- After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.
5. Install the intake manifold. Service and Repair.
6. Connect the fuel hose quick connector. Service and Repair.
7. 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. Throttle Valve Closed Position Learning.
- If electric throttle control actuator is replaced, perform procedures for "Idle Air Volume Learning" after finishing repairs. Idle Air Volume Learning.