Removal And Installation

FUEL INJECTOR AND FUEL TUBE

Removal and Installation


REMOVAL


WARNING:
- Put a "CAUTION: FLAMMABLE" sign in the work shop.
- Be sure to work in a well ventilated area and furnish work shop with a CO2 fire extinguisher.
- Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
1.Release fuel pressure. For Mexico (for Mexico) or Except For Mexico (Except for
Mexico).
2.Remove air cleaner case, mass air flow sensor and air duct assembly. Exploded View.





3.Disconnect quick connector (A) with the following procedure:






CAUTION:
Disconnect quick connector by using quick connector release, not by picking out retainer tabs.





a.Remove quick connector cap.
b.With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.





c.Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position.

CAUTION:
Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.
d.Draw and pull out quick connector straight from fuel tube.

CAUTION:
- Pull quick connector holding "A" position in the figure.
- Never pull with lateral force applied. O-ring inside quick connector may be damaged.
- Prepare container and cloth beforehand as fuel will leakage out.
- Avoid fire and sparks.
- Keep parts away from heat source. Especially, be careful when welding is performed around them.
- Never expose parts to battery electrolyte or other acids.
- Never bend or twist connection between quick connector and fuel feed hose during installation/
removal.





- To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
4.Remove intake manifold. Exploded View.
5.Disconnect sub-harness for fuel injector.
6.Remove fuel tube and fuel injector assembly.





- Loosen mounting bolts in the reverse order as shown in the figure.






CAUTION:
- When removing, be careful to avoid any interference with fuel injector.
- Use a shop cloth to absorb any fuel leakage from fuel tube.
7.Remove fuel injector from fuel tube with the following procedure:





a.Open and remove clip (1).
b.Remove fuel injector (2) from fuel tube (3) by pulling straight.

CAUTION:
- Be careful with remaining fuel that may go out from fuel tube.
- Be careful not to damage fuel injector nozzle during removal.
- Never bump or drop fuel injector.
- Never disassemble fuel injector.

INSTALLATION


CAUTION:
Do not reuse O-rings.
1.Note the following, and install O-rings to fuel injector.

CAUTION:
- Do not reuse O-ring.
- Upper and lower O-rings are different. Be careful not to confuse them.

Except for California:
Fuel tube side: Blue
Nozzle side: Brown
For California:
Fuel tube side: Black
Nozzle side: Green
- Handle O-ring with bare hands. Never wear gloves.
- Lubricate O-ring with new engine oil.
- Never clean O-ring with solvent.
- Check 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, never insert it quickly into fuel tube.
- Insert O-ring straight into fuel tube. Never decenter or twist it.





2.Install fuel injector to fuel tube with the following procedure:





a.Insert clip (3) into clip mounting groove (F) on fuel injector (5).
- Insert clip so that protrusion (E) of fuel injector matches cutout (C) of clip.

CAUTION:
- Never 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 (A) of fuel tube (1)
matches cutout (B) of clip.
- Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip.
c.Check that install in complete by checking that fuel injector does not rotate or come off.
3.Install fuel tube and fuel injector assembly with the following procedure:
a.Insert the tip of each fuel injector into intake manifold adapter.





b.Tighten mounting bolts in numerical order as shown in the figure.

White arrow indicates : Engine front

4.Connect sub-harness for fuel injector.
5.Install intake manifold. Exploded View.
6.Note the following, and connect quick connector to install fuel feed hose.
a.Check the connection for foreign material and damage.





b.Align center to insert quick connector straightly into fuel tube.
NOTE:
The figure shows engine side as an example.
- Insert fuel tube into quick connector until the top spool on fuel tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end.

CAUTION:
- Hold "A" position in the figure when inserting fuel tube into quick connector.
- Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
- Insert until you hear a "click" sound and actually feel the engagement.
- To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
c.Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding "A" position.
Check it is completely engaged (connected) so that it does not come out from fuel feed tube.





d.Install quick connector cap to quick connector connection.
- Install so that the arrow mark on the side faces up.

CAUTION:
- Check that quick connector and fuel tube are securely fit into quick connector cap installation groove.
- If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly.
Check connection again.
7.Install fuel feed hose to hose clamp.
8.Install in the reverse order of removal after this step.