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 fuel injector assembly (for Direct Injection) 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
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point LKA /LDA system

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Pre-collision system
Parking assist monitor system

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Steering sensor zero point calibration Variable gear ratio steering system

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  • Replacement of fuel injector assembly (for Port Injection)

  • Replacement of fuel injector assembly (for Direct Injection)

  • Replacement of throttle body with motor assembly

  • Cleaning the deposits from the throttle body with motor assembly

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

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CAUTION:


  • B004CJ8

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

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


  • B004AP0

    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.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.

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  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. REMOVE NO. 2 DECK BOARD

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  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

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  5. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  6. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    CAUTION:

    To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.

    B004CI7

    1. B004BJ7C02
      B004ANI Front

      Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 2 fuel pipe sub-assembly.

    2. Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.

  7. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH


    1. B004C1E

      Disconnect the fuel pressure sensor connector.

      Note

      Do not pull the wire harness of the fuel pressure sensor excessively.

    2. B004CIZC03
      B004ANI Front

      Remove the bolt. and detach the clamp to disconnect the No. 7 engine wire from the fuel delivery pipe with sensor assembly LH.

    3. B004AALC06
      *1 Bolt
      *2 Nut
      *a Front

      Remove the 2 bolts and 2 nuts.

    4. B004B3AC02

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the cylinder head LH.

    5. B004APWC02
      B004ANI Front

      With the connectors still connected, disconnect the fuel delivery pipe assembly LH.

      Note


      • Make sure that the fuel delivery pipe is disconnected from the fuel delivery pipe assembly LH.

      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

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

    6. Disconnect the 3 fuel injector connectors and remove the No. 7 engine wire.

  8. REMOVE FUEL DELIVERY PIPE RH


    1. Remove the bolt.

    2. B004BTGC02
      B004ANI Front

      Remove the bolt and detach the clamp to disconnect the No. 6 engine wire from the fuel delivery pipe RH.

    3. B004CB6C06
      *1 Bolt
      *2 Nut
      *a Front

      Remove the 2 bolts and 2 nuts.

    4. B004CDGC02

      With the connectors still connected, disconnect the fuel delivery pipe RH.

      Note


      • Be extremely careful not to touch or strike thetips of the fuel injector assemblies.

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

    5. Disconnect the 3 injector connectors and remove the No. 6 engine wire.

  9. REMOVE FUEL INJECTOR ASSEMBLY


    1. B004CE5N01
      *1 No. 2

      Fix the fuel delivery pipe in a vise between aluminum plates.

      Note


      • Do not tighten the vise more than necessary.

      • Do not damage the fuel injector assemblies.

    2. Remove the fuel injector assemblies from the fuel delivery pipe assembly LH and fuel delivery pipe RH.

      Note


      • When removing an injector, pull the injector straight out to avoid damaging the O-ring seal surfaces of the fuel delivery pipe assembly LH and fuel delivery pipe RH.

      • After removing the fuel injector assembly, check that the O-ring, No. 1 fuel injector back-up ring and No. 3 fuel injector back-up ring are not remaining on the fuel delivery pipe. If any of the parts remain on the fuel delivery pipe, remove them.

      • Attach a label to the removed fuel injector assembly to distinguish it from other cylinders.

    3. Remove the nozzle holder clamp from each fuel injector assembly.

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

      Note

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

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

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

  10. REMOVE FUEL INJECTOR SEAL


    1. B004BDS

      Using the tips of a pair of needle nose pliers, pinch and pull one of the fuel injector seals at several points to stretch it. Repeat this for the other fuel injector seal.

      Note


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

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

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