Fuel Injector: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE CABLE
3. DRAIN ENGINE COOLANT
4. REMOVE V-BANK COVER
5. REMOVE COOL AIR INTAKE DUCT SEAL
a. Remove the 7 clips and intake duct seal.
6. REMOVE ENGINE ROOM SIDE COVER LH
a. Remove the 3 clips and side cover.
7. REMOVE ENGINE ROOM SIDE COVER RH
a. Remove the nut, 2 clips and side cover.
8. REMOVE INTAKE AIR CONNECTOR PIPE
9. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY
10. REMOVE NO. 4 V-BANK COVER BRACKET
11. REMOVE NO. 1 V-BANK COVER BRACKET
12. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
13. REMOVE NO. 2 V-BANK COVER BRACKET
14. REMOVE NO. 3 V-BANK COVER BRACKET
15. DISCONNECT ENGINE WIRE
16. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
17. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
a. Using a wrench, remove the 2 pressure pulsation dampers.
b. Remove the fuel delivery pipe, fuel pipe and gasket.
18. REMOVE INTAKE MANIFOLD
19. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Remove the 2 nuts and fuel delivery pipe.
NOTE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.
20. REMOVE NO. 2 DELIVERY PIPE SUB-ASSEMBLY
a. Remove the 2 nuts and fuel delivery pipe.
NOTE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.
21. REMOVE FUEL INJECTOR ASSEMBLY
a. Remove the 8 fuel injectors from the intake manifold.
NOTE:
- When removing an injector, do not apply force in a lateral direction.
- For reinstallation purposes, attach a tag or label to the injector shaft.
b. Remove the O-ring, grommet and insulator.
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
a. Install a new O-ring, grommet and insulator to the injector.
NOTE:
- Check that there is no damage or foreign material in the groove of the injector when installing the injector's O-ring.
- Apply gasoline to a new O-ring and install it to the injector.
b. Push and rotate the injector 45° clockwise and counterclockwise to install it to the delivery pipe.
c. Check that the injector rotates smoothly.
NOTE: When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.
2. INSTALL NO. 2 FUEL DELIVERY PIPE SUBASSEMBLY
a. Install the delivery pipe (with injector) to the intake manifold.
b. With the condition as stated, rotate the injector 45° clockwise and counterclockwise.
NOTE: When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.
c. With the spacer contacting the delivery pipe, install the delivery pipe with the 2 nuts.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Install the delivery pipe (with injector) to the intake manifold.
b. With the condition as stated, rotate the injector 45° clockwise and counterclockwise.
NOTE: When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.
c. With the spacer contacting the delivery pipe, install the delivery pipe with the 2 nuts.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
4. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
a. Using a wrench, install 4 new gaskets and 2 fuel pulsation dampers to the fuel pipe with the 2 bolts.
Torque:
39 N.m (398 kgf.cm, 29 ft.lbf) for use without SST
33 N.m (337 kgf.cm, 24 ft.lbf) for use with SST
5. INSTALL INTAKE MANIFOLD
6. INSTALL NO. 2 FUEL PIPE ASSEMBLY
7. INSTALL ENGINE WIRE
8. INSTALL NO. 3 V-BANK COVER BRACKET
9. INSTALL NO. 2 V-BANK COVER BRACKET
10. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
11. INSTALL NO. 1 V-BANK COVER BRACKET
12. INSTALL NO. 4 V-BANK COVER BRACKET
13. INSTALL THROTTLE BODY ASSEMBLY
14. INSTALL INTAKE AIR CONNECTOR PIPE
15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
16. CHECK FOR FUEL LEAKS
17. ADD COOLANT
18. CHECK FOR COOLANT LEAKS
19. INSTALL V-BANK COVER
20. INSTALL ENGINE ROOM SIDE COVER RH
a. Install the side cover with the 2 clips and nut.
21. INSTALL ENGINE ROOM SIDE COVER LH
a. Install the side cover with the 3 clips.
22. INSTALL AIR INTAKE DUCT SEAL
a. Install the intake duct seal with the 7 clips.
23. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.