FUEL INJECTOR (for Direct Injection) REMOVAL


  1. PRECAUTION

    CAUTION:


    • Do not smoke or be near an open flame when working on the fuel system.

    • Keep gasoline away from rubber or leather parts.

    • Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.

  2. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    Click here

  3. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Remove the fuel pump connector.

    2. A01GMO2E01

      Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the fuel pipe from the fuel pump.

      Note

      Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump.

    3. A01GHWLE01

      Remove the 2 bolts on the delivery pipe side and remove the fuel pipe.

    4. Remove the O-ring, backup ring and E-ring from the fuel pipe.

  4. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Tech Tips

    The removal procedures are the same as the No. 3 fuel pipe.

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    A01GK9J

  6. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

    A01GLVL

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

    A01GKCB

  8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    A01GN7HE06
    Text in Illustration
    *1 Union Nut Wrench

    1. Using a 19 mm union nut wrench, remove the No. 4 fuel pipe sub-assembly.

  9. REMOVE PCV HOSE

    A01GN9W

    1. Remove the PCV hose from the PCV valve.

  10. REMOVE NO. 2 FUEL DELIVERY PIPE

    A01GN04E03

    1. Disconnect the fuel pressure sensor connector.

    2. A01GJ3S

      Disconnect the 4 fuel injector connectors.

    3. A01GLUR

      Remove the 5 bolts and No. 2 fuel delivery pipe from the cylinder head.

      Note


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

      • Pull and remove the No. 2 fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  11. REMOVE FUEL DELIVERY PIPE


    1. A01GIDN

      Disconnect the No. 3 fuel hose.

    2. A01GIJF

      Disconnect the 4 fuel injector connectors.

    3. A01GJ4N

      Remove the 5 bolts and fuel delivery pipe from the cylinder head.

      Note


      • 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.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  12. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01GM5SE01

      Secure the fuel delivery pipe between aluminum plates in a vise and pull out the fuel injector assembly in a straight line.

      Note


      • Pull and remove the fuel injector assembly in a straight line to avoid damage to the seal surface of the fuel delivery pipe O-ring.

      • For reinstallation, attach a tag or label to the fuel injector assembly shaft.

    2. Remove the nozzle holder clamp from the fuel injector assembly.

    3. Remove the O-ring, No. 1 backup ring, No. 2 backup ring, No. 3 backup ring and E-ring from the fuel injector assembly.

  13. REMOVE FUEL INJECTOR SEAL


    1. A01GN80

      Using the tips of needle-nose pliers, pinch and pull one of the 2 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 2 fuel injector seals from the fuel injector assembly.

  14. REMOVE FUEL PIPE SUPPORT SUB-ASSEMBLY


    1. A01GK8UE01
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 No. 2 Fuel Delivery Pipe

      Remove the 4 bolts and 2 fuel pipe support sub-assemblies.

    2. Remove the 2 O-rings, 2 No. 1 backup rings, 2 No. 2 backup rings and 2 E-rings from the 2 fuel pipe support sub-assemblies.

  15. REMOVE FUEL DELIVERY PIPE PLUG


    1. A01GNJ6E01
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 No. 2 Fuel Delivery Pipe

      Using a 6 mm hexagon socket wrench, remove the 2 fuel delivery pipe plugs and 2 gaskets from the fuel delivery pipe and No. 2 fuel delivery pipe.