Fuel Injector: Service and Repair

OVERHAUL







IMPORTANT POINTS - REMOVING

1. CLEAN OFF SURROUNDING AREA OF THE NOZZLE AND THE FUEL LINE CONNECTORS.

NOTICE: If foreign matter is allowed to enter the combustion chamber, engine trouble may result.

2. REMOVE THE INJECTOR.
1. Disconnect of the harness coupler.
2. Remove the leakage pipe.
3. Remove the injection pipe.
4. Remove the bolt of the injection pipe seal and pull it with the injection pipe from the camshaft housing.

NOTICE: Cover open ends of the pipes and fuel supply pump to prevent entry of dirt.







3. REMOVE THE INJECTOR ASSEMBLY.
1. Remove the injector clamp bolt.
2. Pull out the injector assembly taking care not to contact other parts.
3. Remove the O-ring.

NOTICE: Replace the O-ring with a new one.







IMPORTANT POINTS - INSTALLATION

1. INSTALL THE INJECTOR ASSY.
1. Install a new O-ring into the groove of the cylinder head, and then insert the injector.

NOTICE: Apply engine oil to the O-ring, so that the O-ring will not be caught.

2. Install the injector clamp, and install the injector temporarily.

NOTICE: Do not fix the injector clamp before the injection pipe is temporarily installed.

3. Cover the injector with a new injection pipe oil seal, and then install the plate and nut.

NOTICE: Be careful not to apply excessive force to the injector when applying the injection pipe oil seal to it. If the injection pipe oil seal and injector are moved even slightly, it may cause oil leakage or faulty assembling of the injection pipe.

4. Assemble the injection pipe temporarily, and tighten the installation bolt of the injector clamp.

Tightening Torque: 25 N.m {2.5 kgf.m, 18 ft.lbf}

5. Tighten the nut of the injection pipe to the specified torque.

Tightening Torque: 44 N.m {4.5 kgf.m, 32 ft.lbf}

6. Install the leakage pipe with the 5 new gasket and 5 joint bolts.

Tightening Torque: 12.3 N.m {1.25 kgf.m, 91 ft.lbf}

7. Connect the harness couplers.










2. ENTER THE ID CODES IN THE ECU.
1. QR (Quick Response) codes displaying various injector characteristics and the ID codes showing these in numeric form (30 alphanumeric figures) are engraved on the injector head.

NOTICE: When replacing injectors with QR codes, or the engine ECU, it is necessary to record the ID codes (QR codes) in the ECU by using the Diagnostic tool. (If the ID codes of the installed injector are not registered correctly, engine failure such as rough idling and noise will result.)