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 CO2 fire extinguisher.
- Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
REMOVAL
1. Release the fuel pressure. Testing and Inspection.
2. Disconnect battery negative terminal. Removal and Replacement.
3. Remove intake manifold. Exploded View.
4. Disconnect quick connector with the following procedure. Disconnect fuel feed hose from fuel tube.
NOTE:
There is no fuel return path.
a. Remove quick connector cap (1) from quick connector connection.
b. Disconnect fuel feed hose from hose clamp.
c. With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.
d. 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.
e. Draw and pull out quick connector straight from fuel tube.
CAUTION:
- Pull quick connector holding "A" position.
- 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.
5. Disconnect harness connector from fuel injector.
6. Remove fuel tube protector.
- Loosen bolts in the reverse of the order shown.
Arrow Indicates Engine Front
7. Remove the fuel injector and fuel tube assembly.
- Loosen bolts in the reverse of the order shown.
Arrow Indicates Engine Front
CAUTION:
- When removing, be careful to avoid any interference with fuel injector.
- Use a shop cloth to absorb any fuel leaks from fuel tube.
8. Remove the fuel injector (3) from the fuel tube (1) with the following procedure.
a. Open and remove the clip (2).
b. Remove fuel injector (3) from the fuel tube (1) by pulling straight out.
CAUTION:
- Be careful about spilling fuel remaining in fuel tube.
- Be careful not to damage the fuel injector nozzle during removal.
- Never bump or drop fuel injector.
- Never disassemble fuel injector.
INSTALLATION
1. Install new O-rings to the fuel injector.
CAUTION:
- The upper and lower O-rings are different. Be careful not to confuse them.
- 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 the O-ring and its mating part are free of foreign material.
- Be careful not to scratch O-ring with tool or fingernails when installing.
- Do not twist or stretch O-ring. If O-ring is stretched while installing, never insert it into fuel tube immediately.
- Insert O-ring straight into fuel tube. Never angle or twist it.
2. Install the fuel injector (4) onto the fuel tube (1) with the following procedure:
a. Insert the clips (2) into the clip mounting grooves on the fuel injector.
- Insert clip cut-out (D) into fuel injector protrusion (F).
CAUTION:
- Always replace clip with new one.
- Make sure that the clip does not interfere with the Oring. If interference occurs, replace the O-ring.
b. Insert the fuel injector into the fuel tube with clip attached.
- Make sure that the axis is lined up when inserting.
- Insert clip cut-out (C) into fuel tube protrusion (B).
- Make sure that the flange (A) on the fuel tube fits securely in the clip flange fixing groove (E).
c. Make sure that installation is complete by checking that fuel injector does not rotate or come off.
3. Install fuel tube and injector assembly onto cylinder head.
- Tighten bolts in the numerical order shown.
Arrow Indicates Engine Front
CAUTION:
Be careful not to let tip of injector nozzle interfere with other parts.
4. Install fuel tube protector.
- Tighten bolts in the numerical order shown.
Arrow Indicates Engine Front
5. Connect harness connector to fuel injector.
6. Connect fuel feed hose with the following procedure.
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
c. Align center to insert quick connector straightly into fuel tube.
- Insert quick connector to fuel tube until the top spool on fuel tube is inserted completely and the 2nd level spool is positioned slightly below quick connector bottom end.
CAUTION:
- Hold "A" position shown when inserting fuel tube into quick connector.
- Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
- Insert until you hear a "click" sound and actually feel the engagement.
- To avoid mis-identification of engagement with a similar sound, be sure to perform the next step.
d. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding "A" position.
Make sure it is completely engaged (connected) so that it does not come out from fuel tube.
e. Install quick connector cap (1) to quick connector connection.
- Install quick connector cap with the side arrow facing quick connector side (fuel feed hose side).
CAUTION:
- Make sure that the quick connector and fuel tube are securely engaged with the quick connector cap mounting groove.
- Quick connector may not be connected correctly if quick connector cap cannot be installed easily. Remove the quick connector cap, and then check the connection of quick connector again.
f. Install fuel feed hose to hose clamp.
7. Installation of the remaining components is in the reverse order of removal.