Fuel Injector: Service and Repair
Injector Part 1:
Injector Part 2:
REMOVAL
1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR
3. REMOVE FUEL PRESSURE PULSATION DAMPER
Remove the pulsation damper, upper gasket, fuel main hose and lower gasket.
CAUTION:
- Put a shop towel under the delivery pipe.
- Slowly loosen the pulsation damper.
4. REMOVE ACCELERATOR CABLE BRACKET
a. Disconnect the accelerator cable from the engine.
b. Remove the 2 nuts and accelerator cable bracket.
5. DISCONNECT ENGINE WIRE PROTECTOR FROM UPPER INTAKE MANIFOLD
a. Remove and disconnect these parts:
- PCV hose from PCV valve
- VSV for EVAP from upper intake manifold
- Accelerator cable clamp from upper intake manifold
- No.1 V-bank cover bracket from upper intake manifold
- No.2 V-bank cover bracket from upper intake manifold
- No.3 V-bank cover bracket from upper intake manifold
b. Remove the 2 bolts, and disconnect the engine wire protector from the upper intake manifold.
c. Disconnect the engine wire clamp from the No.1 engine hanger.
6. DISCONNECT ENGINE WIRE FROM RH DELIVERY PIPE
Disconnect the 2 wire clamps on the engine wire from the brackets on the delivery pipe
7. REMOVE DELIVERY PIPES AND INJECTORS
NOTE:
- Be careful not to drop the injectors when removing the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.
a. Remove the bolt holding the clamp on the fuel return pipe to the LH delivery pipe.
b. Remove the bolt, 2 union bolts, 4 gaskets and front fuel pipe.
c. Disconnect the 8 injector connectors.
d. Remove the 4 nuts holding the delivery pipes to the lower intake manifold.
e. Remove the 2 delivery pipes, 8 injectors, 4 spacers and 8 insulators.
f. Remove the O-ring and grommet from each injector.
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES
NOTE:
- Be careful not to drop the injectors when installing the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.
a. Install a new grommet to each injector.
b. Apply a light coat of gasoline to a new O-rings and install it to each injector.
c. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 8 injectors.
d. Position injector connector outward.
e. Place the 4 spacers and 8 new insulators on the intake manifold.
f. Place the 2 delivery pipes and injectors assemblies on the lower intake manifold.
g. Temporarily install the 4 nuts.
h. Install the front fuel pipe with the bolt, 4 new gaskets and 2 union bolts.
Torque:
39 N.m (400 kgf.cm, 29 ft.lbf) for union bolts
7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt
i. Install the bolt holding the clamp on the fuel return pipe to the LH delivery pipe.
Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)
j. Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.
k. Position injector connector outward.
l. Tighten the 4 nuts holding the delivery pipes to the lower
m. intake manifold.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
n. Connect the 8 injectors connectors.
2. INSTALL ENGINE WIRE TO LH DELIVERY PIPE
Install the 2 wire clamps on the engine wire to the brackets on the delivery pipe.
3. INSTALL ENGINE WIRE PROTECTOR
a. Connect the engine wire clamp to the No.1 engine hanger.
b. Install the engine wire protector with the 2 bolts.
c. Install and connect these parts:
- PCV hose to PCV valve
- VSV for EVAP to upper intake manifold
- Accelerator cable clamp to upper intake manifold
- No.1 V-bank cover bracket to upper intake manifold
- No.2 V-bank cover bracket to upper intake manifold
- No.3 V-bank cover bracket to upper intake manifold
4. INSTALL ACCELERATOR CABLE BRACKET
a. Install the accelerator cable bracket with the 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the engine.
5. INSTALL FUEL PRESSURE PULSATION DAMPER
6. INSTALL INTAKE AIR CONNECTOR
7. INSTALL V-BANK COVER