Fuel Injector: Service and Repair
FUEL INJECTOR AND FUEL TUBE
CAUTION: Do not remove or disassemble parts unless instructed as shown in the figure.
Removal and Installation
REMOVAL
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.
^ To avoid the danger of being scalded, do not drain engine coolant when the engine is hot.
1. Remove engine cover with power tool.
2. Release fuel pressure.
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage.
CAUTION: Perform this step when the engine is cold.
4. Remove fuel feed hose (with damper) from fuel sub-tube.
NOTE: There is no fuel return route.
CAUTION:
^ While hoses are disconnected, plug them to prevent fuel from draining.
^ Do not separate damper and hose.
5. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as the following:
a. Remove quick connector cap from quick connector connection on right member side.
b. Disconnect fuel feed hose (with damper) from bracket hose clamp.
c. Disconnect quick connector from centralized under-floor piping as follows:
CAUTION: Disconnect quick connector by using quick connector release [SST: - (J-45488)], not by picking out retainer tabs.
i. With the sleeve side of quick connector release facing quick connector, install quick connector release onto centralized under-floor piping.
ii. 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.
iii. Draw and pull out quick connector straight from centralized under-floor piping.
CAUTION:
^ Pull quick connector holding A position as shown in the figure.
^ 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 (with damper) 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.
6. Remove intake manifold collectors (upper and lower).
7. Disconnect harness connector from fuel injector.
8. Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly.
CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
9. Remove spacers on intake manifold.
10. Remove fuel injector from fuel tube as follows:
a. Open and remove clip.
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
^ Be careful with remaining fuel that may go out from fuel tube.
^ Be careful not to damage injector nozzles during removal.
^ Do not bump or drop fuel injector.
^ Do not disassemble fuel injector.
11. Remove fuel sub-tube and fuel damper.
INSTALLATION
1. Install fuel damper and fuel sub-tube.
^ When handling new O-rings, be careful of the following caution:
CAUTION:
^ Handle O-ring with bare hands. Do not wear gloves.
^ Lubricate O-ring with new engine oil.
^ Do not 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, do not insert it quickly into fuel tube.
^ Insert new O-ring straight into fuel tube. Do not decenter or twist it.
^ Insert fuel damper and fuel sub-tube straight into fuel tube.
^ Tighten mounting bolts evenly in turn.
^ After tightening mounting bolts, make sure that there is no gap between flange and fuel tube.
2. Install new O-rings to fuel injector, paying attention to the following.
CAUTION:
^ Upper and lower O-ring are different. Be careful not to confuse them.
Fuel tube side Blue
Nozzle side Brown
^ Handle O-ring with bare hands. Do not wear gloves.
^ Lubricate O-ring with new engine oil.
^ Do not 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, do not insert it quickly into fuel tube.
^ Insert O-ring straight into fuel injector. Do not decenter or twist it.
3. Install fuel injector to fuel tube as follows:
a. Insert clip into clip mounting groove on fuel injector. Insert clip so that protrusion A of fuel injector matches cutout A of clip.
CAUTION:
^ Do not reuse clip. Replace it with a new one.
^ Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
^ Insert it while matching it to the axial center.
^ Insert fuel injector so that protrusion B of fuel tube matches cutout B of clip.
^ Make sure that fuel tube flange is securely fixed in flange fixing groove on clip.
c. Make sure that installation is complete by checking that fuel injector does not rotate or come off. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
4. Install spacers on intake manifold.
5. Install fuel tube and fuel injector assembly to intake manifold.
CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts.
^ Tighten mounting bolts in two steps in numerical order as shown in the figure.
1st step: 10.1 Nm (1.0 kg-m, 7 ft. lbs.)
2nd step: 23.6 Nm (2.4 kg-m, 17 ft. lbs.)
6. Connect injector sub-harness.
7. Install intake manifold collectors (upper and lower).
8. Install fuel sub-tube on rear end of intake manifold collector (lower).
9. Connect fuel feed hose (with damper).
^ Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube.
^ Insert fuel damper straight into fuel sub-tube.
^ Tighten mounting bolts evenly in turn.
^ After tightening mounting bolts, make sure that there is no gap between flange and fuel sub-tube.
10. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping connection as follows:
a. Make sure no foreign substances are deposited in and around centralized under-floor piping and quick connector, and no damage on them.
b. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end.
c. Align center to insert quick connector straightly into centralized under-floor piping.
^ Insert quick connector to centralized under-floor piping until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector.
CAUTION:
^ Hold A position as shown in the figure when inserting centralized under-floor piping 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 misidentification of engagement with a similar sound, be sure to perform the next step.
d. Pull quick connector by hand holding A position. Make sure it is completely engaged (connected) so that it does not come out from centralized under-floor piping.
e. Install quick connector cap to quick connector connection.
^ Install quick connector cap with arrow on surface facing in direction of quick connector (fuel feed hose side).
CAUTION: If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check the connection again.
11. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1. Turn ignition switch ON (with the engine stopped). With fuel pressure applied to fuel piping, make sure there are no fuel leaks at connection points.
NOTE: Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, make sure again that there are no fuel leaks at connection points.
CAUTION: Do not touch the engine immediately after stopped, as the engine becomes extremely hot.