Removal And Installation
FUEL INJECTOR AND FUEL TUBE
Removal and Installation
CAUTION:
- Apply new engine oil before installing the parts, as shown above.
- Do not remove or disassemble parts unless instructed as shown.
REMOVAL
1.Remove engine room cover. Refer to "Removal and Installation" Removal And Installation.
2.Release the fuel pressure. Refer to "Work Procedure" Testing and Inspection.
3.Disconnect the battery negative terminal. Refer to "Removal and Installation (Battery)" Removal And Installation.
4.Remove the air duct hose and resonator. Refer to "Exploded View" Exploded View.
5.Remove quick connector cap (1) from the fuel feed side (B) and the fuel tube side (A).
6.Disconnect the fuel hose quick connector at the fuel tube side using Tool (D).
Tool number: 16441 6N210 (J-45488)
CAUTION:
- 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.
- Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leaks and entry of foreign materials.
- Do not reuse O-ring.
a.With the sleeve (E) side of Tool (D) facing quick connector, install Tool onto fuel tube.
b.Insert Tool into quick connector until sleeve contacts and goes no further (A). Hold the Tool on that position.
CAUTION:
Inserting the Tool hard will not disconnect quick connector. Hold Tool where it contacts and goes no further.
c.Hold the fuel tube in the location (B) and pull the quick connector straight out in direction (C) from the fuel tube.
7.Disconnect the EVAP canister purge volume control solenoid.
8.Remove the PCV hose from the rocker cover.
9.Disconnect sub-harness for injectors at engine front side, and remove it from bracket.
10.Disconnect the fuel injector harness connectors.
11.Loosen the bolts in the reverse order shown, then remove fuel tube and fuel injectors as an assembly.
12.Remove the fuel injectors from the fuel tube, (if necessary).
a.Release the clip.
b.Pull fuel injector straight out of the fuel tube.
CAUTION:
- Be careful not to damage the nozzle.
- Avoid any impact, such as dropping the fuel injector.
- Do not disassemble or adjust the fuel injector.
INSTALLATION
1.Install new O-rings on the fuel injector.
CAUTION:
- Do not reuse O-rings.
- Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side: Black
Nozzle side: Green
- Handle O-rings with bare hands only. Do not wear gloves.
- Do not clean O-rings with solvent.
- Make sure that O-ring and its mating part are free of foreign material.
- Be careful not to scratch O-rings during installation.
- Do not twist or stretch the O-ring. If the O-ring was stretched while it is attached, do not insert it into the fuel tube immediately.
2.Install the fuel injector (5) into the fuel tube (1) with the following procedure:
(2): O-ring (black)
(4): O-ring (green)
a.Insert the new clip (3) into the clip mounting groove (F) on fuel injector (5).
- Insert the clip (3) so that protrusion (E) of fuel injector (5)
matches cutout (C) of the clip (3).
CAUTION:
- Do not reuse clip (3), 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 (5) into fuel tube (1) with clip (3) attached.
- Insert fuel injector (5) so that protrusion (A) of fuel tube (1)
matches cut-out (B) of the clip (3).
- Check that fuel tube flange (G) is securely fixed in flange groove (D) on the clip (3).
c.Check that installation is complete by checking that fuel injector (5) does not rotate or come off.
3.Install fuel tube and fuel injector assembly with the following procedure.
a.Insert the tip of each fuel injector into intake manifold.
b.Tighten the bolts to specification in the numerical order as shown.
CAUTION:
After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leaks.
4.Connect the fuel hose quick connector.
a.Make sure no foreign substances are deposited in and around the fuel tube and quick connector, and there is no damage to them.
b.Thinly apply new engine oil around the fuel tube tip end.
c.Align center to insert quick connector straight onto fuel tube.
d.Insert fuel tube into quick connector (1) until the top spool (B) on fuel tubes is inserted completely and the second level spool (C)
is positioned slightly below the quick connector bottom end.
CAUTION:
- Hold at position (A) as shown, when inserting the fuel tube into the quick connector.
- Carefully align to center to avoid inclined insertion to prevent damage to the O-ring inside the quick connector.
- Insert the fuel tube 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.
- Do not reuse O-ring.
e.Before clamping the fuel hose with the hose clamp, pull the quick connector hard by hand, holding at the (A) position, as shown. Make sure it is completely engaged (connected) so that it does not come off of the fuel tube.
NOTE:
Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
f.Install quick connector cap (1) over fuel hose side (B) and fuel tube side (A).
NOTE:
Direct arrow mark on quick connector cap (1) to fuel hose side.
5.Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Make sure there are no fuel leaks at connections as follows:
1.Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
2.Start the engine and rev it up and check for fuel leaks at connections.
- Perform procedures for "Throttle Valve Closed Position Learning" after finishing repairs. Refer to EC179, "Work Procedure".
- If electric throttle control actuator is replaced, perform procedures for "Idle Air Volume Learning" after finishing repairs. Refer to "Work Procedure" Work Procedure.
WARNING:
Do not touch engine immediately after stopping as engine is extremely hot.
NOTE:
Use mirrors for checking on connections out of the direct line of sight.