FUEL INJECTOR(for Direct Injection) REMOVAL

PROCEDURE


  1. REMOVE INTAKE MANIFOLD

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  2. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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  3. DISCONNECT NO. 5 ENGINE WIRE


    1. A01W0L9

      Remove the 2 bolts and disconnect the No. 5 engine wire from the fuel delivery pipe sub- assembly.

    2. Disconnect the 4 direct fuel injector assembly connectors.

    3. Disconnect the fuel pressure sensor connector.

  4. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01W2HD

      Remove the 3 bolts, 2 nuts and fuel delivery pipe sub-assembly with the direct fuel injector assemblies.

      Text in Illustration
      B001O8N Bolt
      B001OAO Nut

      Note


      • Make sure not to touch or strike the tips of the direct fuel injector assemblies.


      • Pull and remove the fuel delivery pipe sub-assembly in a straight line without tilting it.

  5. REMOVE DIRECT FUEL INJECTOR ASSEMBLY


    1. A01W4RFE03
      *1 NO. 2

      Secure the fuel delivery pipe sub-assembly in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

      Note


      • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe sub-assembly O-ring.


      • Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.

    2. Remove the nozzle holder clamp from each direct fuel injector assembly.

    3. Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.

    4. Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.

    5. Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.

  6. REMOVE FUEL INJECTOR SEAL


    1. A01W04A

      Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

      Note


      • Excessively pinching the fuel injector seal may damage the groove of the direct fuel injector assembly.


      • If a direct fuel injector assembly is dropped or the tip of a direct fuel injector assembly is struck, replace it with a new one.

    2. Remove the fuel injector seal from each direct fuel injector assembly.