Fuel Injector: Service and Repair

Fuel Injector And Associated Parts:

REMOVAL

CAUTION: Before removing the fuel injectors, be absolutely sure to eliminate the fuel pressure in the fuel rail. To do this, remove the pump relay and start the engine. Wait for the engine to stall.

When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage.

1. Disconnect battery ground cable.




2. Remove Fuel filler cap (1).

1. Remove common chamber.
- Refer to removal procedure for Common Chamber.
2. Remove fuel pipe (rail to pump).
3. Disconnect connector of fuel pressure sensor and injector.
4. Remove joint pipe of fuel rail.
5. Remove fuel rail.




6. Remove O-ring and back up ring.
7. Remove spring clip.




8. Remove fuel injector with tool J-46910, Sliding hammer 5042.

Repair for Tip Seal
1. Use long-nose pliers to pull and cut the old TIP seal from the injector. Be careful not to damage the injector surfaces.




2. Install TIP seal with tool J-46911.
3. Place the new TIP seal (2) on the protector (1).
Align the thick end of protector with the tip of the injection nozzle.
Use pusher tool (3) to force the TIP seal into the nozzle groove.




4. Pull the protector and the pusher tool from the nozzle.
5. Use resizing tool (4) to twist and shape the TIP seal until it assumes the correct taper.
6. Carefully wipe away any dirt or other foreign material adhering to the TIP seal and cylinder seal surfaces (foreign material will result in combustion gas leakage).
7. Apply engine oil to the new TIP seal surfaces.

INSTALLATION
1. Install O-ring and back up ring to injector.

NOTE: Do not reuse O-ring and back up ring.

2. Install spring clip.
3. Install the injector.
Apply engine oil to the TIP seal faces.

NOTE: Carbon deposits on the head seal and injector tip seal surfaces will result in fuel leakage. Use a soft brush to carefully remove any carbon deposits. Take care not to damage the seals.

4. Install fuel rail.

Torque: 25 Nm (18.4 lb ft)

5. Install joint pipe of fuel rail.

Torque: 10 Nm (7.4 lb ft)

6. Connect connector of fuel pressure sensor and injector.
7. Install fuel pipe (rail to pump) and joint pipe.

Torque: 10 Nm (7.4 lb ft)

8. Install fuel filler cap.
9. Install common chamber.