Removal and Installation

Fuel Injector and Fuel Tube: Removal and Installation [QR25DE]

CAUTION:

Do not remove or disassemble parts unless instructed.

Removal

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.

1) Release fuel pressure. Refer to [Fuel Pressure Check: QR25DE] Testing and Inspection.
2) Disconnect the fuel quick connector on the engine side.





a) Remove quick connector cap.





b) With the sleeve side of Tool facing quick connector, install Tool onto fuel tube.











c) Insert Tool into quick connector until sleeve contacts and goes no further. 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.

d) Pull the quick connector out straight from the fuel tube.

CAUTION:
- Pull quick connector holding it at the (A) position, as shown.
- Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
- Do not reuse O-rings.
- Prepare container and cloth beforehand as fuel will leak out.
- Avoid fire and sparks.
- Do not expose parts to battery electrolyte or other acids.
- Do not bend or twist connection between quick connector and fuel feed hose during removal and installation.
- Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials.






3) Remove intake manifold. Refer to [Intake Manifold: Removal and Installation] Intake Manifold Removal and Installation.
4) Disconnect harness connector from fuel injector.
5) Loosen bolts in reverse order as shown and remove fuel tube and fuel injector assembly.






CAUTION:
- Be careful to avoid any interference with fuel injector.
- Use a shop cloth to absorb any fuel leaks from fuel tube.

6) Remove fuel injector from fuel tube as follows:





a) Carefully open and remove clip.
b) Remove fuel injector from fuel tube by pulling straight.

CAUTION:
- Be careful with remaining fuel that may leak out from fuel tube.
- Do not reuse O-rings.
- Do not damage fuel injector nozzles during removal.
- Do not bump or drop fuel injectors.
- Do not disassemble fuel injectors.

Installation

1) Install new O-rings to fuel injector, paying attention to the following.

CAUTION:
- Upper and lower O-rings are different colors.






- Handle O-ring with bare hands. Do not wear gloves.
- Lubricate O-ring with new engine oil.
- Do not reuse O-rings.
- Do not clean O-ring with solvent.
- Make sure 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.
- Do not twist or stretch O-ring. If O-ring was stretched while it was being attached, allow it to retract before inserting it into fuel tube.
- Insert new O-ring straight into fuel tube. Do not angle or twist it.

2) Install fuel injector to fuel tube.





a) Insert clip into clip mounting groove on fuel injector.
- Insert new clip so that protrusion of fuel injector matches cutout of clip.

CAUTION:
- Do not reuse clip. Replace it with a new one.
- Do not reuse O-rings.
- Do not allow the clip to interfere with the O-ring. If interference occurs, replace O-ring.

b) Insert the fuel injector into the fuel tube with the clip attached.
- Insert it while matching it to the axial center.
- Insert fuel injector so that protrusion of fuel tube matches cutout of clip.
- Make sure that fuel tube flange is securely fixed in flange fixing groove on clip.
c) Make sure that installation is complete by checking that the fuel injector does not rotate or come off.
- Make sure that protrusions of the fuel injectors are aligned with cutouts of clips after installation.
3) Install fuel tube and fuel injector assembly as follows:

CAUTION:
Do not let the tip of the injector nozzle come in contact with other parts.

a) Insert the tip of each fuel injector into intake manifold.
b) Tighten bolts in two steps in numerical order as shown.











4) Connect harness connectors to fuel injectors.
5) Install intake manifold. Refer to [Intake Manifold: Removal and Installation] Intake Manifold Removal and Installation.
6) Connect quick connector at the engine side as follows:
a) Check the connection for foreign material and damage.
b) Align center to insert quick connector straight into fuel tube.






NOTE:
The figure shows the engine side as an example.

- Insert quick connector to fuel tube until the top spool on fuel tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end.

CAUTION:
- Hold (A) position as shown when inserting fuel tube into quick connector.
- Do not reuse O-rings.
- Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
- Insert 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.

c) Before clamping fuel feed hose with quick connector cap, pull quick connector hard by hand holding (A) position. Make sure it is completely engaged (connected) so that it does not come out from fuel feed tube.
d) Install quick connector cap to quick connector connection. (engine side)





- Install so that the arrow mark on the side faces up.

CAUTION:
- Make sure that quick connector and fuel tube are securely fit into quick connector cap installation groove.
- If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check the connection again.

7) Install fuel feed hose to hose clamp.
8) Installation is in the reverse order of removal after this step.

Inspection after Installation

- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to [Recommended Fluids and Lubricants [for USA and Canada] [1][2]Maintenance ] (United States and Canada) or [Recommended Fluids and Lubricants [for Mexico] ] (Mexico).
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.

NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items:






*Power steering fluid, brake fluid, etc.