Fuel Injector: Service and Repair
INJECTORREMOVAL
1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR
3. REMOVE FUEL PRESSURE PULSATION DAMPER
Remove the pulsation damper, the upper gasket, the fuel main hose and the lower gasket.
CAUTION:
- Put a shop towel under the delivery pipe.
- Slowly loosen the pulsation damper.
4. DISCONNECT ENGINE WIRE PROTECTOR FROM UPPER INTAKE MANIFOLD
a. Remove and disconnect these parts:
- PCV hose from the PCV valve
- VSV for EVAP from the upper intake manifold
- No.1 V-bank cover bracket from the upper intake manifold
- No.2 V-bank cover bracket from the upper intake manifold
- No.3 V-bank cover bracket from the upper intake manifold
- No.4 V-bank cover bracket from the 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.
5. DISCONNECT ENGINE WIRE FROM RH DELIVERY PIPE
Disconnect the 2 wire clamps on the engine wire from the brackets on the delivery pipe
6. REMOVE DELIVERY PIPES AND INJECTORS
NOTE:
- Be careful not to drop the injectors when removing the delivery pipes.
- Since the O-ring may be stuck to the injector, do not put a side load on it at the removal.
a. Remove the bolt holding the clamp on the fuel return pipe to the LH delivery pipe.
b. Remove the bolt, the 2 union bolts, the 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, the 8 injectors, 4 spacers and the 8 insulators.
f. Remove the O-ring and the grommet from each injector.
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES
NOTE:
- Be careful not to drop the injectors when installing the delivery pipes.
- Since the O-ring may be stuck to the injector, do not put a side load on it at the removal.
a. Install a new grommet to each injector.
b. Apply a light coat of gasoline to new O-rings and install them 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 the injectors assemblies on the lower intake manifold.
g. Temporarily install the 4 nuts.
h. Install the front fuel pipe with the bolt, the 4 new gaskets and the 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 in that case.
k. Position the injector connector outward.
l. Tighten the 4 nuts holding the delivery pipes to the lower.
m. intake manifold.
Torque: 21 N.m (214 kgf.cm, 15 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. Connect the PCV hose to the PCV valve.
d. Connect VSV EVAP to the upper intake manifold.
e. Install the No.1 V-bank cover bracket to the upper intake manifold.
f. Install the No.2 V-bank cover bracket to the upper intake manifold.
g. Install the No.3 V-bank cover bracket to the upper intake manifold.
h. Install the No.4 V-bank cover bracket to the upper intake manifold.
4. INSTALL FUEL PRESSURE PULSATION DAMPER
5. INSTALL INTAKE AIR CONNECTOR
6. INSTALL V-BANK COVER