FUEL INJECTOR(for Direct Injection) INSTALLATION

PROCEDURE


  1. INSTALL FUEL INJECTOR SEAL


    1. A01XR38C04
      *a Area to be Cleaned

      Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the direct fuel injector assembly and its grooves.

      Note


      • Do not clean the tip of the direct fuel injector assembly.

      • Do not use a wire brush to clean 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. A01XQUWC03
      *a SST (Guide)
      *b Chamfer

      Apply engine oil to the direct fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the direct fuel injector assembly with the chamfer facing the tip of the direct fuel injector assembly as shown in the illustration.

      SST
      09260-39021   ( 09261-03020 )
    3. A01XR4BC03
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect

      Install a new fuel injector seal to SST (holder).

      SST
      09260-39021   ( 09261-03011 )

      Note

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal.

    4. A01XQY1C03
      *a SST (Holder)
      *b SST (Guide)

      Install SST (holder) with the fuel injector seal to the tip of the direct fuel injector assembly. Slide the fuel injector seal downward into the direct fuel injector assembly groove with your fingers as shown in the illustration.

      SST
      09260-39021   ( 09261-03011, 09261-03020 )

      Tech Tips

      Check that the fuel injector seal is seated in the direct fuel injector assembly groove as shown in the illustration.

    5. A01XQKJC04
      *a SST (Guide)

      Slowly slide SST (guide) toward the tip of the direct fuel injector assembly. When the direct fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the direct fuel injector assembly groove.

      SST
      09260-39021   ( 09261-03020 )

      Note

      Be sure that the fuel injector seal is not pinched between SST (guide) and the edge of the direct fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      Tech Tips


      • Set SST (guide) so that its bottom surface is flush with the fuel injector seal.

      • If it is difficult to slide SST (guide) upward, slowly wiggle it from side to side while sliding it up the direct fuel injector assembly little by little.

    6. A01XQDDC03
      *a Normal
      *b Protruding
      *c Deformed
      *d Correct
      *e Incorrect

      After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the direct fuel injector assembly groove.

      Note

      If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

  2. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing a direct fuel injector assembly.



    1. A01XR23C01
      *1 Direct Fuel Injector Assembly
      *2 C-ring
      *3 Injector Vibration Insulator
      *a Taper

      Install a new injector vibration insulator and a new C-ring to the direct fuel injector assembly.

      Note


      • Install the taper of the injector vibration insulator by aligning it with the taper of the direct fuel injector assembly.

      • Check that the C-ring is securely seated in the groove of the direct fuel injector assembly.

    2. Install a new O-ring and new No. 1 fuel injector back-up ring to the direct fuel injector assembly as shown in the illustration.

      A01XQ18C01
      *1 No. 1 Fuel Injector Back-up Ring *2 O-ring
      *a No. 1 Fuel Injector Back-up Ring Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -

      Note


      • Check that there is no foreign matter or damage on the O-ring groove of the direct fuel injector assembly.

      • Make sure that the No. 1 fuel injector back-up ring is installed in the correct orientation.

      • Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.

      • Check that the opening of the No. 1 fuel injector back-up ring is not overlapped or stretched as shown in the illustration.

      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

    3. A01XQ0JC03
      *1 Direct Fuel Injector Assembly
      *2 No. 3 Fuel Injector Back-up Ring
      *a Notch

      With the notch of a new No. 3 fuel injector back-up ring facing downward, install the direct fuel injector assembly to the No. 3 fuel injector back-up ring as shown in the illustration.

      Note


      • Make sure that the No. 3 fuel injector back-up ring is installed in the correct orientation.

      • After installing the No. 3 fuel injector back-up ring, make sure there is no damage or foreign matter.

    4. Install the nozzle holder clamp to each direct fuel injector assembly.

    5. A01XRG8C03
      *a Protrusion
      *b Positioning Hole
      B002DP3 No Gap

      Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe LH, fuel delivery pipe RH and insert the direct fuel injector assembly.

      Note


      • Make sure that there is no foreign matter or damage inside the direct fuel injector assembly installation holes (fuel delivery pipe LH and fuel delivery pipe RH).

      • Do not allow gasoline to get on the O-rings or inside the installation holes.

      • If it is difficult to insert the direct fuel injector assembly, apply new engine oil to the chamfer of the direct fuel injector assembly installation hole of the fuel delivery pipe LH and fuel delivery pipe RH. Be careful not to allow the direct fuel injector assembly to fall out of the fuel delivery pipe LH or fuel delivery pipe RH.

      • Do not tilt the direct fuel injector assembly when inserting it into the fuel delivery pipe LH and fuel delivery pipe RH.

      • Check that there is no gap between the fuel delivery pipe LH, fuel delivery pipe RH and the nozzle holder clamp.

      • A01XPYIC02
        *a QR Code
        *b Flow Classification Number

        Make sure the 4 direct fuel injector assemblies have the same flow classification number 1, 2 or 3 (the number to the left of the QR code) on each bank (8 direct fuel injector assemblies with the same flow classification number is also okay).

  3. INSTALL FUEL DELIVERY PIPE RH


    1. Apply lubricant to the direct fuel injector assembly installation holes of the cylinder head sub-assembly.

    2. A01XRFZC06
      *a Protruding enough to install nut

      Temporarily install the fuel delivery pipe RH so that the stud bolts protrude enough to install the nuts.

      Note


      • 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.

      • Check that there is no foreign matter or damage on the direct fuel injector assembly installation holes of the cylinder head sub-assembly.

      • When installing the fuel delivery pipe RH, push it in evenly without tilting it.

    3. A01XRHUC02
      B002DP3 Bolt
      B002CU5 Nut

      Install the fuel delivery pipe RH by uniformly tightening the 3 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration again.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note

      Make sure that there is no oil on the bolt threads and nut.

    5. Connect the 4 direct fuel injector assembly connectors.

  4. INSTALL FUEL DELIVERY PIPE LH


    1. Apply lubricant to the direct fuel injector assembly installation holes of the cylinder head LH.

    2. A01XRFZC06
      *a Protruding enough to install nut

      Temporarily install the fuel delivery pipe LH so that the stud bolts protrude enough to install the nuts.

      Note


      • 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.

      • Check that there is no foreign matter or damage on the direct fuel injector assembly installation holes of the cylinder head LH.

      • When installing the fuel delivery pipe LH, push it in evenly without tilting it.

    3. B002E6TC02
      B002DP3 Bolt
      B002CU5 Nut

      Install the fuel delivery pipe LH by uniformly tightening the 3 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration again.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note

      Make sure that there is no oil on the bolt threads and nut.

    5. Connect the 4 direct fuel injector assembly connectors.

  5. INSTALL CASE SEPARATOR

    Click here

  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. Connect the No. 4 fuel pipe sub-assembly to the fuel delivery pipe LH and tighten the union nut by hand.

    2. Connect the No. 4 fuel pipe sub-assembly to the fuel delivery pipe RH and tighten the union nut by hand.

    3. A01XRKWC01
      *1 Fuel Delivery Pipe LH
      *2 Fuel Delivery Pipe RH
      *3 Case Separator
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length
      *c Protector

      Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe LH side of the No. 4 fuel pipe sub-assembly.

      Torque:
      Specified tightening torque
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

    4. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe RH side of the No. 4 fuel pipe sub-assembly.

      Torque:
      Specified tightening torque
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      After installing the No. 4 fuel pipe sub-assembly, check that the protector of the No. 4 fuel pipe sub-assembly contacts the case separator.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

  7. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH


    1. Install the No. 2 engine cover sub-assembly LH.

  8. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

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  9. PERFORM INITIALIZATION


    1. Perform "Inspection After Repair" after replacing a direct fuel injector assembly.