Fuel Injector: Service and Repair
REPLACEMENT1. DISCHARGE FUEL SYSTEM PRESSURE
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT WIPER ARM HEAD CAP
4. REMOVE FR WIPER ARM LH
5. REMOVE FR WIPER ARM RH
6. REMOVE COWL TOP VENTILATOR LOUVER SUB ASSY
7. REMOVE WINDSHIELD WIPER MOTOR ASSY
8. REMOVE COWL TOP TO COWL BRACE INNER NO.1
a. Remove the 2 bolts and the cowl top to cowl brace inner No. 1.
9. REMOVE COWL TOP PANEL SUB ASSY OUTER FRONT
a. Remove the wire harness clamp.
b. Remove the grommet.
c. Remove the 7 bolts and the cowl top panel outer front.
10. REMOVE V BANK COVER SUB ASSY
11. REMOVE AIR CLEANER CAP SUB ASSY
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.
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 the emission control valve set.
13. REMOVE INTAKE AIR SURGE TANK
a. Disconnect 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 2 set nuts of the pressure feed tube.
g. Remove the 2 bolts and the engine hunger No. 1.
h. Remove the 2 bolts and the surge tank stay No. 1.
i. Remove the 2 bolts and the surge tank stay No. 2.
j. Using a socket hexagon wrench 8, remove the 4 bolts.
k. Remove the 2 nuts, 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 ASSY NO.1
a. Remove the bolt and 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 ASSY
a. Disconnect the 6 fuel injector connectors.
b. Remove the 4 bolts and the 2 fuel delivery pipes together with the 6 fuel injectors.
NOTE: Be careful not to drop the fuel injectors when removing the delivery pipe.
c. Remove the 4 delivery pipe No. 1 spacers (*1) and the 6 insulators (*2) from the intake manifold.
d. Pull out the fuel injector from the fuel delivery pipe.
16. INSTALL FUEL INJECTOR ASSY
a. Install new grommets to the each fuel injector.
b. Apply a light coat of spindle oil or gasoline to new O-rings, and install it to the 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 forth to install it in the fuel delivery pipe.
NOTE:
- Be careful not to twist the O-ring.
- After installing the fuel injectors, 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 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.
17. INSTALL FUEL PIPE SUB ASSY 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)
18. 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 2 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.
19. INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
20. INSTALL AIR CLEANER CAP SUB ASSY
21. ADD ENGINE COOLANT
22. CHECK FOR FUEL LEAKS
23. CHECK FOR ENGINE COOLANT LEAKS
24. INSTALL V BANK COVER SUB ASSY
25. INSTALL COWL TOP PANEL SUB ASSY OUTER FRONT
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
26. INSTALL COWL TOP TO COWL BRACE INNER NO.1
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
27. INSTALL WINDSHIELD WIPER MOTOR ASSY
28. INSTALL COWL TOP VENTILATOR LOUVER SUB ASSY
29. INSTALL FR WIPER ARM RH
30. INSTALL FR WIPER ARM LH
31. INSTALL FRONT WIPER ARM HEAD CAP