FUEL INJECTOR(for Direct Injection) INSTALLATION

PROCEDURE


  1. INSTALL FUEL INJECTOR SEAL


    1. A01WYSCC04
      *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 fuel injector set and its grooves.

      Note


      • Do not clean the tip of the fuel injector set.

      • Do not use a wire brush to clean the fuel injector set.

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

    2. A01WXPHC03
      *a SST (Guide)
      *b Chamfer

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

      SST
      09260-39021   ( 09261-03020 )
    3. A01WYRWC03
      *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. A01WXW8C03
      *a SST (Holder)
      *b SST (Guide)

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

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

      Tech Tips

      Check that the fuel injector seal covers the circumference of the fuel injector set groove as shown in the illustration.

    5. A01WYL6C04
      *a SST (Guide)

      Slowly slide SST (guide) toward the tip of the fuel injector set. When the fuel injector set 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 fuel injector set groove.

      SST
      09260-39021   ( 09261-03020 )

      Note

      Make sure the fuel injector seal is not pinched between SST (guide) and the edge of the fuel injector set 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 fuel injector set little by little.

    6. A01WXTTC03
      *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 fuel injector set 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 FUEL INJECTOR SET

    Tech Tips

    Perform "Inspection After Repair" after replacing the fuel injector set.

    Click here


    1. A01WYAIC01
      *1 Fuel Injector Set
      *2 C-ring
      *3 Injector Vibration Insulator
      *a Tapered Side

      Install a new injector vibration insulator and a new C-ring to each fuel injector set.

      Note


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

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

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

      A01WXCPC01
      *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 fuel injector set.

      • 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. A01WXVSC03
      *1 Fuel Injector Set
      *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 fuel injector set 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 fuel injector set.

    5. A01WYLXC03
      *a Protrusion
      *b Positioning Hole
      B004FMB No Gap

      Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe sub-assembly and insert the fuel injector set.

      Note


      • Make sure that there is no foreign matter or damage inside the fuel injector set 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 fuel injector set, apply new engine oil to the chamfer of the fuel injector set installation hole of the fuel delivery pipe sub-assembly. Be careful not to allow the fuel injector set to fall out of the fuel delivery pipe sub-assembly.

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

        A01WYRAC03
        *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.

      • A01WYMVC02
        *a QR Code
        *b Flow Classification Number

        Make sure the 4 fuel injector sets have the same flow classification number 1, 2 or 3 (the number to the left of the QR code).

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


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

    2. A01WYPHC06
      *a Nut can be attached

      Temporarily install the fuel delivery pipe sub-assembly so that the stud bolts protrude enough to install the nuts.

      Note


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

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

      • When installing the fuel delivery pipe sub-assembly, push it in evenly without tilting it.

    3. A01WXQTC02
      B004FMB Bolt
      B004EIV 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:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

    4. Connect the 4 fuel injector set connectors.

    5. Connect the wire harness to the fuel delivery pipe sub-assembly with the 2 bolts.

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

    6. Connect the fuel pressure sensor connector.

  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  5. INSTALL INTAKE MANIFOLD

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  6. PERFORM INITIALIZATION


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

      Click here