Removal And Installation

FUEL INJECTOR AND FUEL TUBE


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.
- Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
- To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove engine cover and engine room cover (RH and LH). Exploded View.
2. Release fuel pressure. Testing and Inspection.





3. Remove the fuel feed hose (2) on the fuel feed damper side with quick connector release (commercial service tool: J-45488) as per the followings steps.

1. : Quick connector cap
Arrow : Engine Front

CAUTION:
Use the quick connector release for removing the fuel feed hose on the centralized under-floor piping side as well as the fuel feed damper side although the shape of the quick connector is different.
a. Remove quick connector cap from quick connector connection.





b. With the sleeve side (B) of quick connector release (A) facing to quick connector (D), install quick connector release onto fuel feed hose.

1 : Fuel feed damper
C : Insert and retain

c. 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.
d. Pull out quick connector straight from fuel feed damper.

CAUTION:
- Pull quick connector holding position (E) as shown in the figure.
- Never 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.
- Never expose parts to battery electrolyte or other acids.
- Never bend or twist connection between quick connector and fuel feed hose during installation/removal.





- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags (A) or something similar.
4. Remove air duct. Exploded View.
5. Remove electric throttle control actuator. Exploded View.
6. Remove fuel hose (center).
- The procedure for removing the quick connector is the same as for removing the fuel feed damper.

CAUTION:
Disconnect quick connector by using quick connector release (commercial service tool: J-45488), not by picking out retainer tabs.
7. Remove fuel tube and fuel injector assembly.





- Loosen mounting bolts (b) first. Then loosen mounting bolts
(a) shown in the figure.

1 : Fuel tube (bank 2)
2 : Fuel tube (bank 1)
: Engine front

CAUTION:
Never tilt it, or remaining fuel in pipes may flow out from pipes.





8. Remove fuel injector (1) from fuel tube (3) as per the following:

A : Installed condition
B : Clip mounting groove
C : Protrusion

a. Open and remove clip (2).
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.
- Never bump or drop fuel injector.
- Never disassemble fuel injector.
9. Disconnect sub harness connector from fuel injectors.
10. Remove fuel damper and fuel feed damper, if necessary.

INSTALLATION





1. Install fuel damper (4) as per the following:

1 : Fuel damper cap

a. Install new O-ring (3) to fuel tube (bank 1) (2) as shown. When handling new O-ring, pay attention to the following caution items:

CAUTION:
- Handle O-ring with bare hands. Never wear gloves.
- Lubricate O-ring with new engine oil.
- Never clean O-ring with solvent.
- Check 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 new O-ring straight into fuel tube. Never decenter or twist it.
b. Install spacer (A) to fuel damper. Insert fuel damper straight into fuel tube (bank 1).

CAUTION:
- Insert straight, check that the axis is lined up.
- Insert fuel damper at 130 N (13.3 kg, 29.2 lb) or less to prevent damage to the parts
- Insert fuel damper until the rim (C) reaches the cap flange (B).
c. Tighten mounting bolts evenly in turn.
- After tightening mounting bolts, check that there is no gap between flange and fuel tube (bank 1).
2. Install fuel feed damper.
- Handling procedure of O-ring is the same as that of fuel damper.
- Insert fuel feed damper straight into fuel tube (bank 2).

CAUTION:
Insert fuel feed damper at 147 N (15 kg, 33.1 lb) or less to prevent damage to the parts
- Tighten mounting bolts evenly in turn.
- After tightening mounting bolts, check that there is no gap between flange and fuel tube (bank 2).
3. Install new O-rings to fuel injector paying attention to the following caution.

CAUTION:
- Upper and lower O-ring are different. Be careful not to confuse them.

Fuel tube side : Black
Nozzle side : Green

- Handle O-ring with bare hands. Never wear gloves.
- Lubricate O-ring with new engine oil.
- Never clean O-ring with solvent.
- Check 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 injector. Never decenter or twist it.





4. Install fuel injector (3) to fuel tube (1) as per the following:

2 : O-ring (black)
4 : O-ring (green)

a. Insert clip (5) into clip mounting groove (B) on fuel injector.
- Insert clip so that protrusion (C) of fuel injector matches cutout
(E) of clip.

CAUTION:
- Never 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 (G) of fuel tube matches cutout (F) of clip.
- Check that fuel tube flange (A) is securely fixed in flange fixing groove (D) on clip.

CAUTION:
Insert fuel injector at 147 N (15 kg, 33.1 lb) or less to prevent damage to the parts c. Check that installation is complete by checking that fuel injector does not rotate or come off.
- Check that protrusions of fuel injectors and fuel tube are aligned with cutouts of clips after installation.
5. Install fuel tube and fuel injector assembly.





- Tighten mounting bolts (a) first. Then tighten mounting bolts
(b) shown in the figure.

1 : Fuel tube (bank 2)
2 : Fuel tube (bank 1)
Arrow: Engine front

Tightening Torque: 1st step : 10.1 N-m (1.0 kg-m, 7 ft-lb)
Tightening Torque: 2nd step : 23.6 N-m (2.4 kg-m, 17 ft-lb)

CAUTION:
- Be careful not to let tip of injector nozzle come in contact with other parts.
- Insert fuel injector at 147 N (15 kg, 33.1 lb) or less to prevent damage to the parts
6. Install quick connecters as per the following:
- Unless otherwise indicated, the installation to the engine side and centralized under-floor piping side is exactly alike.
a. Check no foreign substances are deposited in and around fuel piping and quick connector, and no dam- age on them.
b. Thinly apply new engine oil around fuel piping from tip end to spool end.
c. Align center to insert quick connector straightly into fuel piping.

Fuel hose (center) and centralized under-floor piping side:





- Visually confirm that the two retainer tabs (A) are connected to the quick connector (B).

CAUTION:
- 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.

Fuel feed damper side:





- Insert quick connector to fuel feed damper piping until top spool (2) is completely inside quick connector and 2nd level spool (3) exposes just below quick connector.

B : Fitted condition
Arrow : Upright insertion

CAUTION:
- Hold (A) position as shown in the figure when inserting fuel feed hose (1) 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 position (A). Check it is completely engaged (connected) so that it does not come out from fuel piping (1).





e. Install quick connector cap (3) to quick connector connection.

1 : Fuel tube (bank 1)
2 : Fuel hose (center)

- Install quick connector cap with arrow (A) on surface facing the direction of quick connector.

CAUTION:
If cap cannot be installed smoothly, quick connector may have not be installed correctly. Check connection again.

NOTE:
Figure shows an example fuel feed damper side.
7. Install in the reverse order of removal.