Removal And Installation

FUEL INJECTOR AND FUEL TUBE


Removal and Installation


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.

CAUTION:
- Apply new engine oil to parts before installing the parts, as shown above.
- Do not remove or disassemble parts unless instructed as shown.

REMOVAL
1. Release the fuel pressure. Testing and Inspection.
2. Disconnect the battery negative terminal. Removal and Replacement.





3. Remove quick connector cap (1) from quick connector connection.





1 : Quick connector cap

4. Disconnect fuel feed hose from hose clamp.

NOTE:
There is no fuel return path.
5. With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.





6. 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.
7. Draw and pull out quick connector straight from fuel tube.

CAUTION:
- Pull quick connector holding (A) position.
- 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 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.
8. Remove intake manifold. Component Removal And Installation.




Arrow Indicates Engine front


9. Remove fuel tube bolts.
- Loosen bolts in reverse order as shown.

10. Remove the fuel tube and fuel injector assembly.

CAUTION:
- When removing, be careful to avoid any interference with fuel injector.
- Use a shop cloth to absorb any fuel leaks from fuel tube.
11. Remove fuel injector from the fuel tube with the following procedure:
a. Open and remove the clip.
b. Remove fuel injector from the fuel tube by pulling straight.

CAUTION:
- Be careful about spilling fuel remaining in fuel tube.
- Be careful not to damage the fuel injector nozzle during removal.
- Never bump or drop fuel injector.
- Never disassemble fuel injector.

INSTALLATION
1. Install new O-rings to the fuel injector.

CAUTION:
- The upper and lower O-rings are different. Be careful not to confuse them.





. Handle O-ring with bare hands. Never wear gloves.
. Lubricate O-ring with new engine oil.
. Never clean O-ring with solvent.
. Make sure that the O-ring and its mating part are free of foreign material.
. Be careful not to scratch O-ring with tool or fingernails when installing.
. Do not twist or stretch O-ring. If O-ring was stretched while installing, never insert it into fuel tube immediately.
- Insert O-ring straight into fuel tube. Never angle or twist it.









2. Install fuel injector (4) to fuel tube (1) with the following procedure:

a. Insert clip (2) into clip groove (F) on fuel injector.
- Insert clip so that protrusion (G) of fuel injector matches cutout (D) 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 (B) of fuel tube matches cut-out (C) of clip.
- Make sure that fuel tube flange (A) is securely fixed in flange fixing groove (E) on clip.
c. Make sure that installation is complete by making sure that fuel injector does not rotate or come off.
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.

CAUTION:
Be careful not to let tip of injector nozzle interfere with other parts.




Arrow Indicates Engine front


4. Tighten bolts in numerical order as shown.

5. Installation of the remaining components is in the reverse order of removal.

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:
Never touch the engine immediately after it is stopped, as the engine becomes extremely hot.