Fuel Injector: Service and Repair
FUEL INJECTOR REMOVAL AND INSTALLATIONREMOVAL
1. Drain engine coolant.
2. Disconnect cables.
- Disconnect these cables from the throttle body:
- Cruise control actuator cable
- Accelerator cable
- Throttle cable
3. Disconnect No.2 PCV hose from throttle body.
4. Remove air cleaner hose.
5. Remove EGR valve and vacuum modulator.
6. Remove bolt holding heater inlet pipe and air intake chamber.
7. Disconnect hoses.
- Disconnect hoses:
(1) No. 1 PCV hose from PCV valve
(2) Vacuum sensing hose from fuel pressure regulator
(3) No. 2 water bypass hose from water bypass pipe
(4) EVAP hose from pipe
(5) Brake booster vacuum hose from air intake chamber
8. Disconnect connectors.
- Disconnect these connectors:
- Throttle position sensor connector
- IAC valve connector
- Connector for emission control valve set assembly
- EGR gas temperature sensor connector
9. Disconnect PS reservoir.
- Remove the 3 bolts, and disconnect the reservoir.
10. Remove engine oil dipstick.
11. Disconnect ground strap.
12. Remove intake manifold stay.
- Remove the 2 bolts and intake manifold stay.
13. Remove air intake chamber assembly.
- Disconnect hoses:
(1) 2 vacuum hoses from TVV for EVAP
(2) No. 1 water bypass hose from cylinder head
- Remove the 6 bolts, 2 nuts, the air intake chamber, throttle body assembly and 2 gaskets.
14. Remove fuel return pipe.
- Disconnect the fuel hose from the fuel pressure regulator.
- Remove the 2 bolts and fuel return pipe.
15. Remove fuel inlet pipe.
- Remove the 2 union bolts, bolt, 4 gaskets and fuel pipe.
16. Remove delivery pipe and injectors.
- Disconnect the 6 injector connectors.
- Remove the 3 bolts and delivery pipe together with the 6 injectors.
NOTICE: Be careful not to drop the injectors when removing the delivery pipe.
- Remove the 6 insulators and 3 spacers from the intake manifold.
- Pull out the 6 injectors from the delivery pipe.
- Remove the O-ring and grommet from each injector.
INSTALLATION
1. Install delivery pipe and injectors.
- Install a new grommet to the injector.
- Apply a light coat of gasoline to a new O-ring, and install it to the injector.
- While turning the injector left and right, install it to the delivery pipe.
- Install the 6 injectors.
- Position the injector connector upward.
- Place 6 new insulators and the 3 spacers in position on the intake manifold.
- Place the 6 injectors together with the delivery pipe in position on the intake manifold.
- Temporarily install the 3 bolts holding the delivery pipe to the intake manifold.
- Check that the injectors rotate smoothly.
HINT:
- If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings.
- Replace the O-rings.
- Position the injector connector upward.
- Tighten the 3 bolts holding the delivery pipe to the intake manifold.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
- Connect the 6 injector connectors.
HINT: The No. 1, No. 3 and No. 5 injector connectors are gray, and the No. 2, No. 4 and No. 6 injector connectors are brown.
2. Install fuel inlet pipe.
- Install the fuel inlet pipe with 4 new gaskets, the 2 union bolts and bolt.
Torque:
Union bolt: 29 N.m (300 kgf.cm, 22 ft.lbf)
Bolt: 20 N.m (200 kgf.cm, 14 ft.lbf)
3. Install fuel return pipe.
- Install the fuel return pipe with the 2 bolts.
Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)
- Connect the fuel return hose to the fuel pressure regulator.
4. Install air intake chamber assembly.
- Install 2 new gaskets, the air intake chamber and throttle body assembly with the 6 bolts and 2 nuts.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
- Connect hoses:
(1) 2 vacuum hoses to TVV for EVAP
(2) No. 1 water bypass hose to cylinder head
5. Install intake manifold stay.
- Install the intake manifold stay with the 2 bolts.
Torque: 36 N.m (360 kgf.cm, 26 ft.lbf)
6. Install ground strap.
7. Install engine oil dipstick.
8. Connect PS reservoir.
- Connect the reservoir with the 3 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
9. Connect connectors.
- Connect these connectors:
- Throttle position sensor connector
- IAC valve connector
- Connector for emission control valve set assembly
- EGR gas temperature sensor connector
10. Connect hoses.
- Connect hoses:
(1) No. 1 PCV hose to PCV valve
(2) Vacuum sensing hose to fuel pressure regulator
(3) No. 2 water bypass hose to water bypass pipe
(4) EVAP hose to pipe
(5) Brake booster vacuum hose to air intake chamber
11. Install bolt holding heater inlet pipe and air intake chamber.
Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)
12. Install EGR valve and vacuum modulator.
13. Connect cables.
- Connect these cables to the throttle body:
- Cruise control actuator cable
- Accelerator cable
- Throttle cable
14. Install air cleaner hose.
15. Connect No. 2 PCV hose to throttle body.
16. Fill with engine coolant.
17. Check for fuel leaks.