FUEL INJECTOR (for Direct Injection) INSTALLATION

INSTALL FUEL INJECTOR SEAL

1. 

   Text in Illustration

   *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 direct fuel injector assembly and its grooves.

   Note

   
   

   • Do not clean the tip of the direct fuel injector assembly.

   
   

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

   
   

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

2. 

   Text in Illustration

   *a	SST (Guide)
   *b	Chamfer

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

   SST

   09260-39021   ( 09261-03020 )

3. 

   Text in Illustration

   *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. 

   Text in Illustration

   *a	SST (Holder)
   *b	SST (Guide)

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

   SST

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

   Note

   Check that the fuel injector seal is seated in the direct fuel injector assembly groove as shown in the illustration.

5. 

   Text in Illustration

   *a	SST (Guide)

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

   SST

   09260-39021   ( 09261-03020 )

   Note

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

6. 

   Text in Illustration

   *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 direct fuel injector assembly groove.

   Note

   If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

INSTALL DIRECT FUEL INJECTOR ASSEMBLY

1. 

   Text in Illustration

   *1	Direct Fuel Injector Assembly
   *2	C-ring
   *3	Injector Vibration Insulator
   *a	Taper

   Install a new injector vibration insulator and a new C-ring to the direct fuel injector assembly.

   Note

   
   

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

   
   

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

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

   

   Text in Illustration

   *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 direct fuel injector assembly.

   
   

   • 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. 

   Text in Illustration

   *1	Direct Fuel Injector Assembly
   *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 the direct fuel injector assembly 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 direct fuel injector assembly.

5. 

   Text in Illustration

   *a	Protrusion
   *b	Positioning Hole
   	No Gap

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

   Note

   
   

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

   
   

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

   
   

   • Check that there is no gap between the fuel delivery pipe sub-assembly and the nozzle holder clamp.

   
   

   • 

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

     Text in Illustration

     *a	QR Code
     *b	Flow Classification Number

INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

CONNECT NO. 5 ENGINE WIRE

1. Connect the fuel pressure sensor connector.

2. Connect the 4 direct fuel injector assembly connectors.

3. Connect the No. 5 engine wire to the fuel delivery pipe sub-assembly with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL INTAKE MANIFOLD

Click here

PERFORM INITIALIZATION

1. Perform "Inspection After Repair" after replacing a direct fuel injector assembly Click here.