Fuel Injector: Service and Repair

Fuel Injector:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DRAIN ENGINE COOLANT
3. REMOVE FR WIPER ARM LH
4. REMOVE FR WIPER ARM RH
5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
6. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
8. REMOVE WINDSHIELD WIPER LINK ASSEMBLY

9. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
a. Disconnect the rain sensor connector. (w/ Auto Wiper)
b. Remove the 2 wire harness clamps.
c. Remove the grommet.
d. Remove the 6 nuts, and then remove 2 front shock absorber caps. (w/ Air Suspension)
e. Remove the 4 set nuts of the shock absorber. (w/o Air Suspension)
f. Remove the 4 bolts and 2 nuts, and then remove the cowl top panel outer.
g. Tighten the 6 set nuts of the shock absorber.

Torque: 80 N.m (815 kgf.cm, 59 ft.lbf)

10. REMOVE V-BANK COVER SUB-ASSEMBLY

11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
a. Disconnect the mass air flow meter connector.
b. Disconnect the 4 vacuum hoses.
c. Disconnect the ventilation hose No. 2.
d. Remove the fuel vapor feed hose from the 2 hose clamps.
e. Loosen the 2 air cleaner cap bolts.
f. Loosen the air cleaner hose clamp bolt, and remove the air cleaner cap.
g. Remove the air cleaner filter element.

12. REMOVE EMISSION CONTROL VALVE SET

a. Disconnect the 2 VSV connectors.
b. Remove the wire harness clamp.

c. Disconnect the fuel vapor feed hose No. 1.
d. Disconnect the fuel vapor feed hose No. 2.
e. Disconnect the 2 vacuum hoses.
f. Remove the clamp.
g. Remove the 2 nuts, and then remove the emission control valve set.

13. REMOVE INTAKE AIR SURGE TANK

a. Disconnect the throttle motor connector.
b. Disconnect the water by-pass hose No. 3.
c. Disconnect the water by-pass hose No. 2.
d. Disconnect the union to check valve hose.

e. Disconnect the ventilation hose.

f. Remove the 3 nuts and separate the pressure feed tube.

g. Remove the 2 bolts, and then remove the engine hunger No. 1.
h. Remove the 2 bolts, and then remove the surge tank stay No. 1.
i. Remove the 2 bolts, and then remove the surge tank stay No. 2.

j. Using a socket hexagon wrench 8, remove the 4 bolts.
k. Remove the 2 nuts, and then remove the emission control valve bracket and the intake air surge tank.
l. Remove the gasket from the intake air surge tank.

14. SEPARATE FUEL PIPE SUB-ASSEMBLY NO.1

a. Remove the bolt and separate the fuel pipe No. 1.
b. Remove the fuel pressure pulsation damper and the 2 gaskets.
c. Remove the fuel pipe No. 2 union bolt and the 2 gaskets.

15. REMOVE FUEL INJECTOR ASSEMBLY

a. Disconnect the 6 fuel injector connectors.

b. Remove the 4 bolts, and then remove the 2 fuel delivery pipes together with the 6 fuel injectors.

NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

c. Remove the 4 delivery pipe No. 1 spacers (A) and the 6 insulators (B) from the intake manifold.

d. Pull out the fuel injector from the fuel delivery pipe.

INSTALLATION

1. INSTALL FUEL INJECTOR ASSEMBLY
a. Install new grommets to each fuel injector.
b. Apply a light coat of spindle oil or gasoline to new Orings, and install them to each fuel injector.

c. Apply a light coat of spindle oil or gasoline on the place where the fuel delivery pipe contacts the O-ring.

d. Push the fuel injector while twisting it back and force to install it in the fuel delivery pipe.

NOTE:
- Be careful not to twist the O-ring.
- After installing the fuel injector, check that they turns smoothly. If not, reinstall it with a new O-ring.

e. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.

f. Place the 2 fuel delivery pipes and the 6 fuel injectors together to the intake manifold.

NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

g. Temporarily install 4 bolts which are used to attach the fuel delivery pipe to the intake manifold.
h. Check that the fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, the probable cause is incorrect installation of O-ring. Replace with the O-ring.
i. Tighten the 4 bolts.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

j. Connect the 6 fuel injector connectors.

2. INSTALL FUEL PIPE SUB-ASSEMBLY NO.1
a. Install 2 new gaskets and the fuel pipe No. 2 union bolt.

Torque: 33 N.m (331 kgf.cm, 24 ft.lbf)

b. Install 2 new gaskets and the fuel pressure pulsation damper.

Torque: 33 N.m (331 kgf.cm, 24 ft.lbf)

c. Install the fuel pipe No. 1 with the bolt.

Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)

3. INSTALL INTAKE AIR SURGE TANK
a. Install a new gasket to the intake air surge tank.
b. Install the intake air surge tank and the emission control valve bracket with the 2 nuts.

Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)

c. Using a socket hexagon wrench 8, tighten the 4 bolts.

Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)

d. Install the surge tank stay No. 2 with the 2 bolts.

Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)

e. Install the surge tank stay No. 1 with the 2 bolts.

Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)

f. Install the engine hunger No. 1 with the 2 bolts.

Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)

g. Install the pressure feed tube with the 3 nuts.

Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)

h. Connect the ventilation hose.
i. Connect the union to check valve hose.
j. Connect the water by-pass hose No. 2.
k. Connect the water by-pass hose No. 3.
l. Connect the throttle motor connector.

4. INSTALL EMISSION CONTROL VALVE SET

Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)

5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

6. CHECK CONNECTION OF VACUUM HOSE

7. ADD ENGINE COOLANT

8. CHECK FOR ENGINE COOLANT LEAKS

9. CHECK FOR FUEL LEAKS

10. INSTALL V-BANK COVER SUB-ASSEMBLY

11. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) (Set bolts and nuts of the cowl top panel outer)

Torque: 80 N.m (815 kgf.cm, 59 ft.lbf) (Set nuts of the shock absorber)

12. INSTALL WINDSHIELD WIPER LINK ASSEMBLY

13. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

14. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

15. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

16. INSTALL FR WIPER ARM RH

17. INSTALL FR WIPER ARM LH