Fuel Injector: Service and Repair

REMOVAL

1. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLD
2. REMOVE CYLINDER HEAD COVER
(a) Disconnect the 4 high-tension cords from the clamp on the cylinder head cover.
(b) Disconnect the 4 high-tension cords from the spark plugs.





(c) Remove the 2 bolts, and disconnect the cable bracket from the intake manifold.
(d) Disconnect the accelerator cable from the clamp on the intake manifold.
(e) Disconnect the PCV hose from the intake manifold.





(f) Disconnect the engine wire protector from the 2 mounting bolts of the No.2 timing belt cover in the sequence shown.
(g) Remove the oil filler cap.
(h) Remove the cylinder head cover.

NOTICE: Cover the cylinder head with a clean cloth to prevent dirt, etc. getting into the cylinder head.

3. REMOVE DELIVERY PIPE AND INJECTORS





(a) Disconnect the air hose from the fuel pressure regulator.
(b) California only:
Disconnect the air hose for the air assist system from the intake manifold port, and remove the air hose.
(c) Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the delivery pipe.





(d) Disconnect the 4 injector connectors.





(e) Remove the bolt, and disconnect the engine wire protector from the LH side of the intake manifold.





(f) Disconnect the engine wire protector from the 2 brackets on the front side of the intake manifold.





(g) Remove the 2 bolts holding the delivery pipe to the cylinder head.





(h) Disconnect the delivery pipe from the 4 injectors.
(i) Pull out the 4 injectors.

NOTICE: Be careful not to drop the injectors.

(j) Remove the 4 insulators (Except California) and 2 spacers from the cylinder head.





(k) Disconnect the fuel return hose from the return pipe, and remove the delivery pipes.
California:
Remove the 2 O-rings, insulator and grommet from each injector.
Except California:
Remove the O-ring and grommet from each injector.

INSTALLATION

1. INSTALL INJECTORS AND DELIVERY PIPE





(a) California:
Install new insulator and grommet to each injector.
(b) Except California:
Install a new grommet to each injector
(c) California:
Apply a light coat of gasoline onto 2 new O-rings, and install them to each injector.
(d) Except California:
Apply a light coat of gasoline onto a new O-ring, and install it to each injector.
(e) Place the delivery pipe between the intake manifold and cylinder head.





(f) Connect the fuel return hose to the return pipe.





(g) Install these parts to the cylinder head:
(1) 2 spacers
(2) Except California:
4 new insulators
(h) While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors.





(i) Position the injector connector upward.
(j) Attach the 4 injectors and delivery pipe assembly to the cylinder head.





(k) Temporarily install the 2 bolts holding the delivery pipe to the cylinder head.
(l) 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.





(m) Position the injector connector upward.





(n) Tighten the 2 bolts holding the delivery pipe to the cylinder head.

Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)





(o) Install the engine wire protector to the 2 brackets on the front side of the intake manifold.





(p) Install the engine wire protector to LH side of the intake manifold with the bolt.





(q) Connect the 4 injector connectors.

HINT: The No.1 and No.3 injector connectors are brown, and the No.2 and No.4 injector connectors are gray.





(r) Connect the fuel inlet hose to the delivery pipe with 2 new gaskets and the union bolt.

Torque: 34 N.m (350 kgf.cm, 25 ft.lbf)

NOTICE: Be careful of the fuel inlet hose installation direction.

(s) Connect the air hose to the fuel pressure regulator.
(t) California only:
Install the air hose for the air assist system to the intake manifold port.

2. INSTALL CYLINDER HEAD COVER
(a) Install the cylinder head cover.
(b) Install the oil filler cap.





(c) Install the engine wire protector to the 2 mounting bolts of the No.2 timing belt cover in the sequence shown.





(d) Connect the PCV hose to the intake manifold.
(e) Install the cable bracket with the 2 bolts.
(f) Install the accelerator cable to the clamp on the intake manifold.
(g) Connect the 4 high-tension cords to the spark plugs.
(h) Install the 4 high-tension cords to the clamp on the cylinder head cover.

3. INSTALL THROTTLE BODY
4. CHECK FOR FUEL LEAKS