Removal and Installation

FUEL INJECTOR AND FUEL TUBE

Removal and Installation


REMOVAL


WARNING:
- Be sure to read "Precaution for Handling High Pressure Fuel System" Precaution For Handling High Pressure Fuel System when working on the high pressure fuel system.
- 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.Release fuel pressure. Refer to the following table:





2.Remove intake manifold. Refer to "Removal and Installation" Removal and Installation.
3.Remove fuel feed tube (pump side) and fuel feed tube (bank side).

CAUTION:
Never reuse fuel feed tube.
4.Remove fuel rail (bank 1) and fuel rail (bank 2).
5.Disconnect harness connector from fuel injectors.
6.Remove fuel injector from cylinder head as per the following:

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.
a.Remove injector holder.





b.Install an injector remover [SST: KV10119600 (-)] (A) to the injector connector side so that cutout (B) of injector remover faces the injector connector side.





- Hook pawl portion (B) of injector remover [SST: KV10119600
(-)] (A) to groove portion (C) of injector.





c.Press down body portion (A) of injector remover [SST:
KV10119600 (-)] until it contacts cylinder head.





d.Tighten injector remover [SST: KV10119600 (-)] clockwise and remove injector from cylinder head.





e.Cut Teflon seal (1) while pinching it. Be careful not to damage injector.
f.Remove insulator from mounting hole of fuel injector of cylinder head.
7.Remove fuel rail pressure sensor from fuel rail (bank 1), if necessary.

INSTALLATION


CAUTION:
Do not reuse O-rings.
1.Install fuel rail pressure sensor to fuel rail (bank 1), if removed.

CAUTION:
- Use a hexagon support tool to install fuel rail pressure sensor. (Do not use open end tool to install fuel rail pressure sensor.)
- Never use fuel rail pressure sensor, if dropped.
2.Install seal ring to fuel injector as per the following:

CAUTION:
- Handle seal ring with bare hands. Never wear gloves.
- Never apply engine oil to seal ring.
- Never clean seal ring with solvent.





a.Install seal guide [SST: KV10119720 (-)] (A) to fuel injector (1).





b.Set seal ring (1) to seal installer [SST: KV10119730 (-)] (A).





c.Straightly insert seal ring (1), which is set in precedent step, to fuel injector as shown in the figure and install.

CAUTION:
Be careful that seal ring does not exceed the groove portion of fuel injector.





d.Insert drift [SST: KV10119710 (-)] (A) to injector and rotate clockwise and counterclockwise by 90�
while pressing seal ring to fit it.






CAUTION:
Be careful to a direction of the tool.
NOTE:
Compress seal ring, because this operation is for rectifying stretch of seal ring caused by installation and for preventing sticking when inserting injector into cylinder head.
3.Install O-ring and backup ring to fuel injector. When handing new O-ring and backup ring, paying attention to the following caution items:

CAUTION:
- Do not reuse O-ring.
- 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 rail. Never decenter or twist it.





- Always install the back up ring (1) in the right direction as instructed.





4.Install fuel injector (1) to fuel rail (2) as per the following:





a.Install fuel injector holder (5) to fuel injector.

CAUTION:
- Never reuse injector holder. Replace it with a new one.
- Be careful to keep fuel injector holder from interfering with O-ring. If interference occurs, replace O-ring.
b.Insert fuel injector into fuel rail with fuel injector holder attached.
- Insert it while matching it to the axial center.
- Insert so that protrusion (A) of fuel injector is aligned to cutout (B).
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 rail are aligned with cutouts of clips after installation.
5.Insert insulator into mounting hole of fuel injector of cylinder head.
6.Install fuel rail and fuel injector assembly to cylinder head.





- Tighten mounting bolts and nuts in two steps in numerical order as shown in the figure.













7.Connect injector harness connector.
8.Install fuel feed tube (bank side) to fuel rail.

CAUTION:
- Never reuse fuel feed tube (bank side).
- When installing fuel feed tube (bank side) to fuel rail, press the flange part to install the tube.
- 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.
- Never scratch O-ring with tools or fingernails when installing fuel feed tube (bank side).
- Insert new fuel feed tube (bank side) straight into fuel rail.
Never decenter or twist the fuel feed tube (bank side) during insertion.





- Tighten mounting bolts in numerical order as shown in the figure.










9.Install fuel feed tube (pump side) (1) to fuel feed tube (bank side) (2) as per the following:






CAUTION:
- When removing fuel feed tube (pump side), always replace fuel feed tube (bank side) together with fuel feed tube (pump side).
- Never reuse fuel feed tube (pump side).
- Never use fuel feed tube (pump side) if its terminal tip is damaged.
- Observe the tightening order and the tightening torque.
a.Apply engine oil to flare screw parts of high pressure pump and tube between banks.
b.Manually tighten 2 flare nuts without using a tool until they are seated to screw thread.

CAUTION:
When temporarily tightening flare nut, place pipe in the center of the nut inner diameter.





c.Tighten mounting bolt (A).





d.Tighten flare nuts in numerical order as shown in the figure.

CAUTION:
Always fit the tool completely with the nut.
10.Install in the reverse order of removal after this step.

CAUTION:
After checking fuel leakage, maintain ten minutes of idling to bleed the fuel line.