Fuel Rail: Service and Repair
FUEL INJECTOR AND FUEL TUBERemoval and Installation
Exploded View EM-35:
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.
^ To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Remove intake manifold collector.
CAUTION: Perform this step when engine is cold.
2. Disconnect the fuel quick connector on the engine side.
^ Using Tool perform the following steps to disconnect the quick connector.
Tool number: - (J-45488)
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 straight out 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.
^ Prepare container and cloth beforehand as fuel will leak out.
^ Avoid fire and sparks.
^ Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials.
3. Remove PCV hose between rocker covers (right and left banks).
4. Disconnect harness connector from fuel injector.
5. Loosen bolts in reverse order as shown, and remove fuel tube and fuel injector assembly.
CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
6. Remove bolts which connects fuel tube (RH) and fuel tube (LH).
7. 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 go out from fuel tube.
^ Be careful not to damage injector nozzles during removal.
^ Do not bump or drop fuel injector.
^ Do not disassemble fuel injector.
8. Disconnect fuel tube (RH) from fuel tube (LH).
9. Loosen bolts, to remove fuel damper cap and fuel damper, if necessary.
INSTALLATION
1. Install fuel damper as follows:
a. Install new O-ring to fuel tube as shown.
^ When handling new O-rings, be careful of the following caution:
CAUTION:
^ Handle O-ring with bare hands. Do not wear gloves.
^ Lubricate O-ring with new engine oil.
^ 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. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.
^ Insert new O-ring straight into fuel tube. Do not twist it.
b. Install spacer to fuel damper.
c. Insert fuel damper straight into fuel tube.
CAUTION:
^ Insert straight, making sure that the axis is lined up.
^ Do not pressure-fit with excessive force.
Reference value: 130 N (13.3 kg, 29.2 lb)
^ Insert fuel damper until "B" is touching "A" of fuel tube.
d. Tighten bolts evenly in turn.
^ After tightening bolts, make sure that there is no gap between fuel damper cap and fuel tube.
2. Install new O-rings to fuel injector, paying attention to the following.
CAUTION:
^ Upper and lower O-ring are different. Be careful not to confuse them.
Fuel tube side: Blue
Nozzle side: Brown
^ Handle O-ring with bare hands. Do not wear gloves.
^ Lubricate O-ring with new engine oil.
^ 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. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.
^ Insert O-ring straight into fuel injector. Do not twist it.
3. Install fuel injector to fuel tube as follows:
a. Insert clip into clip mounting groove on fuel injector.
^ Insert clip so that protrusion "A" of fuel injector matches cutout "A" of clip.
CAUTION:
^ Do not reuse clip. Replace it with a new one.
^ Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
^ Insert it while matching it to the axial center.
^ Insert fuel injector so that protrusion "B" of fuel tube matches cutout "B" 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 fuel injector does not rotate or come off.
^ Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
4. Connect fuel tube (RH) to fuel tube (LH), and tighten bolts temporarily.
^ Tighten bolts with the specified torque after installing fuel tube and fuel injector assembly.
CAUTION:
^ Handle O-ring with bare hands. Do not wear gloves.
^ Lubricate O-ring with new engine oil.
^ 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. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.
^ Insert new O-ring straight into fuel tube. Do not twist it.
5. Install fuel tube and fuel injector assembly to intake manifold.
CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts.
^ Tighten bolts in two steps in numerical order as shown. Fuel injector tube assembly bolts
1st step: 10.1 Nm (1.0 kg-m, 7 ft-lb)
2nd step: 22.0 Nm (2.2 kg-m, 16 ft-lb)
6. Tighten bolts which connects fuel tube (RH) and fuel tube (LH) with the specified torque.
7. Connect fuel injector harness connector.
8. Install intake manifold collector.
9. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
NOTE: Use mirrors for checking at points out of clear sight.
2. Start engine. With engine speed increased, check again for fuel leakage at connection points.
CAUTION: Do not touch engine immediately after stopped, as engine becomes extremely hot.