Fuel Injector: Service and Repair

Fuel Injector:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
a.Discharge fuel system pressure

2. DRAIN ENGINE COOLANT
3. REMOVE FRONT SUSPENSION BRACE SUBASSEMBLY UPPER CENTER (w/ Performance Rod)
a. Remove the 2 nuts and upper brace.

4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

a. Disconnect the MAF meter connector [A].
b. Disconnect the 3 vacuum hoses [B].
c. Disconnect the ventilation hose No. 2 [C].
d. Loosen the air cleaner hose clamp bolt [D] and remove the air cleaner cap.
e. Remove the air cleaner filter element.

6. REMOVE EMISSION CONTROL VALVE SET

a. Disconnect the 2 VSV connectors [A].
b. Remove the wire harness clamp [B].

c. Disconnect the fuel vapor feed hose No. 1 [C].
d. Disconnect the fuel vapor feed hose No. 2 [D].
e. Disconnect the 2 vacuum hoses [E].
f. Remove the clamp [F].
g. Remove the 2 nuts and the emission control valve set.

7. REMOVE INTAKE AIR SURGE TANK

a. Disconnect the throttle motor connector [A].
b. Disconnect the water by-pass hose No. 3 [B].
c. Disconnect the water by-pass hose No. 2 [C].
d. Disconnect the union to check valve hose [D].

e. Disconnect the ventilation hose[E].

f. Remove the 3 nuts and separate the pressure feed tube [F].
g. Remove the 2 bolts and engine hanger No. 1 [G].

h. Remove the 2 bolts and surge tank stay No. 1 [H].
i. Remove the 2 bolts and surge tank stay No. 2 [I].

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

8. REMOVE FUEL PIPE SUB-ASSEMBLY NO.1

a. Remove the bolt and disconnect the fuel pipe No. 1
b. Remove the fuel pressure pulsation damper and gaskets [B].
c. Remove the fuel pipe No. 2 union bolt and 2 gaskets

9. REMOVE FUEL INJECTOR ASSEMBLY

a. Disconnect the 6 fuel injector connectors.

b. Remove the 4 bolts and 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 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 a new grommet to each injector.
b. Apply a light coat of grease or gasoline to a new O-ring, and install it to each injector.
c. Apply a light coat of grease 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 injector, check that it 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 on the intake manifold.

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

g. Temporarily install the 4 bolts which are used to attach the fuel delivery pipe to the intake manifold.

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

h. Tighten the 4 bolts.

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

i. 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 (337 kgf.cm, 24 ft.lbf)

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

Torque: 33 N.m (337 kgf.cm, 24 ft.lbf)

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

Torque: 20 N.m (204 kgf.cm, 15 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 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 (204 kgf.cm, 15 ft.lbf)

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

Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)

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

Torque: 20 N.m (204 kgf.cm, 15 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 N.m (82 kgf.cm, 71 in.lbf)

5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
6. CHECK CONNECTION OF VACUUM HOSE
7. ADD ENGINE COOLANT
8. CHECK ENGINE COOLANT LEAKAGE
9. CHECK FUEL LEAKAGE
a.Check for the fuel leaks

10. INSTALL V-BANK COVER SUB-ASSEMBLY
11. INSTALL FRONT SUSPENSION BRACE SUBASSEMBLY UPPER CENTER (w/ Performance Rod)
a. Install the upper brace with the 2 nuts.

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