FUEL INJECTOR (for Direct Injection) REMOVAL


  1. PRECAUTION

    CAUTION:


    • Do not smoke or work near an open flame when handling 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 assembly and the fuel injector assembly. The fuel in the pipe is highly pressurized.

  2. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. Remove the intake air surge tank assembly Click here.

  5. REMOVE NO. 1 FUEL HOSE


    1. A015YXC

      Remove the 2 fuel pipe clamps.

    2. A0160BNE01

      Pinch the 2 fuel tube connector and then pull out the No. 1 fuel hose.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

    3. A01619JE01

      Lift up the retainer to release its lock.

    4. Pinch the 2 fuel tube connectors and then pull out the No. 1 fuel hose.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

  6. SEPARATE ENGINE WIRE


    1. A015ZSI

      Disconnect the harness clamp and then separate the engine wire.

  7. REMOVE NO. 3 COVER SUB-ASSEMBLY


    1. A01632B

      Remove the bolt and separate the engine wire.

    2. Remove the 2 bolts and bracket.

    3. A0160DB

      Remove the 2 clips and No. 3 cover sub-assembly.

  8. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (for Direct Injection)


    1. Remove the fuel pressure pulsation damper assembly and No. 1 fuel pipe sub-assembly Click here.

  9. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Remove the high pressure side fuel pump assembly connector.

    2. A0162CY

      Secure the union bolt on the fuel pump assembly 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 assembly.

      Note

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

    3. A016187

      Remove the 2 bolts on the delivery pipe side and remove the No. 3 fuel pipe sub-assembly.

  10. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Remove the high pressure side fuel pump assembly connector.

    2. Secure the union bolt on the fuel pump assembly 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 assembly.

      Note

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

      Tech Tips

      Use the same procedure as for the bank 1 side.

    3. A0162DD

      Remove the 2 bolts on the delivery pipe side and separate the No. 2 fuel pipe sub-assembly.

    4. A0160ME

      Remove the bolt and No. 2 fuel pipe sub-assembly.

  11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A0160E4

      Remove the No. 1 engine cover sub-assembly.

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


    1. A0163KT

      Remove the No. 2 engine cover sub-assembly LH.

  13. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A015ZCWE03

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

  14. REMOVE SEPARATOR CASE


    1. A0161F0E03

      Disconnect the fuel pressure sensor connector.

    2. A015Z2V

      Remove the 4 bolts and separator case from the cylinder head.

  15. REMOVE NO. 2 FUEL DELIVERY PIPE (for Direct Injection)


    1. A0162M6

      Disconnect the 4 injector connectors.

    2. A0162DC

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

      Note


      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull the No. 2 fuel delivery pipe straight without tilting it.

    3. A0161WA

      Remove the 4 injector vibration insulators from the cylinder head.

  16. REMOVE FUEL DELIVERY PIPE (for Direct Injection)


    1. A0162VZ

      Disconnect the 4 injector connectors.

    2. A0161AR

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

      Note


      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull the fuel delivery pipe straight without tilting it.

    3. A015ZX7

      Remove the 4 injector vibration insulators from the cylinder head.

  17. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)


    1. A0163BJE01

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

      Note


      • Pull the fuel injector assembly straight out to avoid damage to the seal surface of the fuel delivery pipe and No.2 fuel delivery pipe O-ring.

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

    2. A01601T

      Remove the nozzle holder clamp from the injector assembly.

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

  18. REMOVE FUEL INJECTOR SEAL


    1. A0161WC

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

    2. Remove the 2 fuel injector seals from the fuel injector assembly.

  19. REMOVE FUEL PIPE SUPPORT SUB-ASSEMBLY


    1. A0161QH

      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.

  20. REMOVE FUEL DELIVERY PIPE PLUG


    1. A0160OV

      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.