FUEL INJECTOR(for Direct Injection) REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during direct fuel injector assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Battery terminal is disconnected/reconnected Perform steering sensor zero point calibration Lane departure alert system (w/ Steering Control)

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Pre-collision system
Memorize steering angle neutral point Parking assist monitor system

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  • Replacement of direct fuel injector assembly

  • Replacement of throttle body with motor assembly

  • Cleaning the deposits from the throttle body with motor assembly

  • Replacement of EGR valve assembly

  • Gas leak from exhaust system is repaired

 Inspection after repair

  • Poor idle, etc.

  • Engine start function, etc.

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CAUTION:


  • B006ZQO

    Never perform work on fuel system components near any possible ignition sources.

  • Vaporized fuel could ignite, resulting in a serious accident.


  • B006XC9

    Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.

  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

Note

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  4. REMOVE INTAKE MANIFOLD

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  5. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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  6. REMOVE FUEL DELIVERY PIPE

    Note

    When replacing the fuel delivery pipe, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.


    1. B006WWN

      Disconnect the fuel pressure sensor connector.

    2. Disengage the clamp to disconnect the sensor wire from the fuel delivery pipe.

    3. B006Z19

      Disconnect the 4 direct fuel injector assembly connectors.

      Note

      Make sure to disconnect the connectors carefully.

    4. B006YK6

      Remove the 4 bolts and fuel delivery pipe with the 4 direct fuel injector assemblies from the cylinder head sub-assembly.

      Note


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

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

  7. REMOVE DIRECT FUEL INJECTOR ASSEMBLY


    1. B006XLIN01
      *1 No. 3

      Secure the fuel delivery pipe 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 O-ring.

      • After removing the direct fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the fuel delivery pipe side.

      • 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.

      • Cover the tip of each direct fuel injector assembly to prevent it from being damaged.

    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.

      Note

      Do not damage the area that contacts the O-ring.

    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.

  8. REMOVE FUEL INJECTOR SEAL


    1. B006XVU

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

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