Fuel Injector: Service and Repair
FUEL INJECTOR AND FUEL TUBE
Removal and Installation
CAUTION:
^ Apply new engine oil when installing the parts as specified to do so.
^ Do not remove or disassemble parts unless instructed as shown.
REMOVAL
1. Remove the intake manifold collector. Refer to "Removal and Installation".
2. Disconnect fuel tube quick connector at vehicle piping side.
3. To remove the quick connector cap, hold the sides of the connector, push in the tabs and pull out the tube.
NOTE: If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.
CAUTION:
^ The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
^ Do not use any tools to remove the Quick connector.
^ Keep the resin tube away from heat. Be especially careful when welding near the tube.
^ Prevent acid liquids such as battery electrolyte, etc. from getting on the resin tube.
^ Do not bend or twist the tube during removal or installation.
^ Do not remove the remaining retainer on the tube.
^ When the tube is replaced, also replace the retainer with a new one.
^ To keep the connecting portion clean and to avoid damage and foreign materials entering, cover the ends of the fuel tubes with plastic bags or something similar.
4. Remove the fuel rail with the fuel injectors attached, from the intake manifold. Remove the fuel injector O-rings and use new O-rings for installation.
5. If necessary, remove fuel damper bolts and the fuel dampers. Remove fuel damper O-rings and use new O-rings for installation.
INSTALLATION
1. If necessary, Install fuel damper bolts. Use new O-rings for installation.
Fuel damper bolts : 7.2 - 10.8 (0.8 - 1.1 kg-m, 64 - 95 inch lbs.)
2. Install the fuel rails with fuel injectors attached.
NOTE:
^ Carefully install new O-rings.
^ Lubricate O-rings by lightly coating with new engine oil.
^ Be careful not to damage the O-rings and surfaces for O-ring sealing surfaces. Do not expand or twist O-rings.
^ Discard old clips; replace with new ones.
^ Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
^ Position clips in grooves on the fuel injectors.
^ Align the protrusions of the fuel tube assembly with those of the fuel injectors.
^ After properly inserting the fuel injectors onto the fuel tube assembly, check that the fuel tube protrusions are engaged with those of fuel injectors, and the flanges of the fuel tube assembly are fully encased with the clips.
3. Tighten fuel tube assembly bolts in the order shown, in two steps:
Fuel tube assembly bolts
Step 1 : 9.3 - 10.8 Nm (0.95 - 1.1 kg-m, 6.2 - 7.9 ft. lbs.)
Step 2 : 20.6 - 26.5 Nm (2.1 - 2.7 kg-m, 16 - 19 ft. lbs.)
CAUTION:
^ After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.
4. Install the quick connector as follows:
a. Make sure no foreign substances are deposited in and around the fuel tube and quick connector and that there is no damage.
b. Align the center to insert the quick connector straight onto the fuel tube.
c. Insert the fuel tube until a click is heard.
5. Installation of the remaining components is in the reverse 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.
NOTE: Use mirrors for checking on connections out of the direct line of sight.
CAUTION: Do not touch engine immediately after stopping as engine is extremely hot.