FUEL INJECTOR(for Direct Injection) INSTALLATION

PROCEDURE


  1. INSTALL FUEL INJECTOR SEAL


    1. B005OYXC04
      *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 the direct fuel injector assembly is struck, replace it with a new one.

    2. B005LEMC03
      *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. B005MG7C03
      *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. B005QEMC03
      *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. B005NJEC04
      *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

      Make sure 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. B005NGWC03
      *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.

      Tech Tips

      Use the same procedure to install the other fuel injector seals.

  2. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

    Tech Tips

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

    Click here


    1. B005MHKC01
      *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 each 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 a new No. 1 fuel injector back-up ring to each direct fuel injector assembly as shown in the illustration.

      B005LYTC01
      *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. B005Q9IC03
      *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 each 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. B005L59C03
      *a Protrusion
      *b Positioning Hole
      B005NIZ No Gap

      Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe sub-assembly 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 sub-assembly).

      • 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 sub-assembly. Be careful not to allow the direct fuel injector assembly to fall out of the fuel delivery pipe sub-assembly.

      • Do not tilt the direct fuel injector assembly when inserting it into the fuel delivery pipe sub-assembly.

        B005OLMC03
        *1 O-ring *2 Fuel Delivery Pipe Sub-assembly
        *a Correct *b Incorrect

      • Check that there is no gap between the fuel delivery pipe sub-assembly and the nozzle holder clamp.

      • B005PZ4C02
        *a QR Code
        *b Flow Classification Number

        Make sure the 4 direct fuel injector assemblies have the same flow classification number and that the flow classification number is 1, 2 or 3.

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


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

    2. B005MB9C06
      *a Protruding enough to install nut

      Temporarily install the fuel delivery pipe sub-assembly 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 sub-assembly, push it in evenly without tilting it.

    3. B005PLRC02
      B005NIZ Bolt
      B005LWS Nut

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

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

      Note

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

  4. CONNECT SENSOR WIRE


    1. Connect the fuel pressure sensor connector.

    2. Connect the 4 direct fuel injector assembly connectors.

    3. Connect the sensor wire to the fuel delivery pipe sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  6. INSTALL FUEL PUMP ASSEMBLY

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  7. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  8. INSTALL NO. 1 AIR TUBE

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  9. INSTALL FUEL PUMP PROTECTOR

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  10. INSTALL INTAKE MANIFOLD

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  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  12. INSPECT FOR FUEL LEAK

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  13. PERFORM INITIALIZATION


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

      Click here