Installation

4GR-FSE FUEL: FUEL INJECTOR: INSTALLATION

1. INSTALL FUEL INJECTOR SEAL

(a) Apply engine conditioner to the injector area shown in the illustration. Using a piece of cloth, clean carbon deposits from the injector and its grooves.





Text in Illustration





NOTICE:
* Do not clean the tip of the injector.
* Do not use a wire brush to clean the injector.
* If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

(b) Apply engine oil to the injector contact surface of SST (guide). Then attach SST (guide) to the injector with the tapered inner portion facing the tip of the injector, as shown in the illustration.





Text in Illustration





SST : 09260-39015

09268-03020

(c) Install a new injector seal to SST (holder).





SST : 09260-39015

09268-03010

NOTICE:
Be careful not to install the injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.

(d) Install SST (holder with injector seal) to the tip of the injector. Slide the seal downward into the injector groove (injector connector side) with your fingers, as shown in the illustration.





Text in Illustration





SST : 09260-39015

09268-03010

09268-03020

HINT
Check that the seal covers the circumference of the injector groove as shown in the illustration.

(e) Using SST (holder), gently press downward on the injector seal (injector connector side). Then slowly slide SST (guide) toward the injector tip to settle the seal into the injector groove.





SST : 09260-39015

09268-03010

09268-03020

NOTICE:
Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

HINT
* When using SST (guide) to settle the seal into the groove, SST (guide) only needs to be slid upward to the position labeled A in the illustration.
* After using SST (guide) to settle the seal into the groove, return SST (guide) to its position labeled B in the illustration.

(f) Install a new injector seal to the injector groove (injector tip side) as shown in the illustration.





SST : 09260-39015

09268-03010

09268-03020

(g) Check that the seal covers the circumference of the injector groove as shown in the illustration.





Text in Illustration





SST : 09260-39015

09268-03010

09268-03020

NOTICE:
Make sure that the seal does not slip into the welded groove of the injector shown in the illustration. If it does, replace it with a new one.

(h) Slowly slide SST (guide) toward the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.





Text in Illustration





SST : 09260-39015

09268-03020

NOTICE:
Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

HINT
* Set SST (guide) so that its bottom surface and seal are flush.
* If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.

(i) Using SST (holder), gently press downward on the injector seal (injector tip side). Then slowly slide SST (guide) toward the injector tip to settle the seal into the injector groove.





SST : 09260-39015

09268-03010

09268-03020

NOTICE:
Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

(j) Slowly slide SST (guide) toward the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.





Text in Illustration





SST : 09260-39015

09268-03020

NOTICE:
Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

HINT
* Set SST (guide) so that its bottom surface and the seal are flush.
* If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.

(k) After installing the seals, check that they are not scratched, deformed or protruding from the injector groove.





NOTICE:
If a seal is scratched, deformed or protruding from the groove, replace it with a new one.

2. INSTALL FUEL INJECTOR ASSEMBLY

(a) Install a new O-ring, new backup rings (No. 1, No. 2 and No. 3) and new E-ring to the fuel injector as shown in the illustration.





NOTICE:
* Check that there is no foreign matter or damaged areas in the injector O-ring groove.
* Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
* Make sure that the backup rings and O-ring are installed in the correct order.
* Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
* After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

(b) Install the injector nozzle holder clamp.

(c) Apply gasoline to the O-ring. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.





NOTICE:
* Make sure that there is no gap between the delivery pipe and clamp.
* Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
* Insert the injector straight into the delivery pipe without tilting it.

3. INSTALL NO. 1 FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Install a new injector vibration insulator to the cylinder head.

(b) Apply lubricant to the installation hole of the injector.

(c) Insert the stud bolt into the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.





Text in Illustration





NOTICE:
* If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
* Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
* When inserting the fuel delivery pipe, push it in evenly without tilting it.

(d) Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.





Text in Illustration





Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

(e) Connect the 3 connectors and 2 clamps.

4. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Install new injector vibration insulators to the cylinder head.

(b) Apply lubricant to the installation holes of the injectors.

(c) Insert the stud bolt into the delivery pipe until the screw threads protrude enough so that a nut can be attached.





Text in Illustration





NOTICE:
* If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
* Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
* When inserting the fuel delivery pipe, push it in evenly without tilting it.

(d) Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.





Text in Illustration





Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

(e) Connect the 3 connectors and 3 clamps.

5. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

(a) Install new O-rings, new backup rings (No. 1, No. 2 and No. 3) and new E-rings to the No. 3 fuel pipe as shown in the illustration.





NOTICE:
* Check that there is no foreign matter or damaged areas in the injector O-ring groove.
* Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
* Make sure that the backup rings and O-ring are installed in the correct order.
* Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
* After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
* Check that the fuel pipe installation end is not contaminated with foreign matter and is not damaged.

(b) Apply gasoline to the O-ring.

(c) Press the fuel pipe and delivery pipe together by hand until there is no gap between them. Then install the No. 3 fuel pipe with the 4 bolts.





Text in Illustration





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTICE:
Do not install the No.3 fuel pipe at an angle.

6. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Install a new O-ring, new backup rings (No. 1, No. 2 and No. 3) and new E-ring to the No. 2 fuel pipe as shown in the illustration.





NOTICE:
* Check that there is no foreign matter or damaged areas in the injector O-ring groove.
* Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
* Make sure that the backup rings and O-ring are installed in the correct order.
* Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
* After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
* Check that the No. 3 fuel pipe installation end is not contaminated with foreign matter and is not damaged.

(b) Apply gasoline to the O-ring and connect the fuel pipe to the delivery pipe.





NOTICE:
* Do not install the No. 2 fuel pipe at an angle.
* Do not install the bolt at this time.

7. INSTALL FUEL PUMP ASSEMBLY Installation

8. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Installation

9. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Install the No. 1 fuel pipe sub-assembly with the 2 bolts.





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Connect the 2 fuel hoses.

(c) Connect the No. 3 fuel hose to the No. 1 fuel pipe sub-assembly.

10. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Installation

11. CONNECT WATER HOSE JOINT

(a) Connect the water hose joint with the bolt.





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

12. INSTALL INTAKE MANIFOLD

HINT
Installation.

13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

14. INSPECT FOR FUEL LEAK Fuel System