FUEL INJECTOR(for Direct Injection) INSTALLATION

PROCEDURE


  1. INSTALL FUEL INJECTOR SEAL


    1. B003TAJC05
      *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 fuel injector assembly and its grooves.

      Note


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

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

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

    2. B003UAXC04
      *a SST (Guide)
      *b Chamfer

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

      SST
      09260-39015   ( 09268-03020 )
    3. B003X8ZC02
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect

      Install a new fuel injector seal to SST (holder).

      SST
      09260-39015   ( 09268-03010 )

      Note

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.

    4. B003TK7C02
      *a SST (Holder)
      *b SST (Guide)

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

      SST
      09260-39015   ( 09268-03010, 09268-03020 )

      Tech Tips

      Check that the fuel injector seal covers the circumference of the fuel injector assembly groove as shown in the illustration.

    5. Using SST (holder), gently press downward on the fuel injector seal (fuel injector assembly connector side), then slowly slide SST (guide) toward the fuel injector assembly tip to settle the fuel injector seal into the fuel injector assembly groove.

      B003TV0C03
      *a SST (Holder) *b SST (Guide)
      *c Gently Press *d Correct
      *e Incorrect - -
      SST
      09260-39015   ( 09268-03010, 09268-03020 )

      Note

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      Tech Tips


      • When using SST (guide) to settle the fuel injector seal into the groove, SST (guide) only needs to be slid upward to the position (A) in the illustration.

      • After using SST (guide) to settle the fuel injector seal into the groove, return SST (guide) to its position (B) in the illustration.

    6. B003X8ZC02
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect

      Install a new fuel injector seal to SST (holder).

      SST
      09260-39015   ( 09268-03010 )

      Note

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.

    7. B003UZ9C02
      *a SST (Holder)
      *b SST (Guide)
      *c Welded Groove

      Install a new fuel injector seal to the fuel injector assembly groove (fuel injector assembly tip side) as shown in the illustration.

      SST
      09260-39015   ( 09268-03010, 09268-03020 )

      Note

      Make sure that the fuel injector seal does not slip into the welded groove of the fuel injector assembly shown in the illustration. If it does, replace it with a new one.

      Tech Tips

      Check that the fuel injector seal covers the circumference of the fuel injector assembly groove as shown in the illustration.

    8. B003UB5C02
      *a SST (Guide)

      Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly connector side) as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the fuel injector assembly groove.

      SST
      09260-39015   ( 09268-03020 )

      Note

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      Tech Tips


      • Set SST (guide) so that its bottom surface and the fuel injector seal are flush.

      • If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.

    9. Using SST (holder), gently press downward on the fuel injector seal (fuel injector assembly tip side), then slowly slide SST (guide) toward the fuel injector assembly tip to seat the fuel injector seal into the fuel injector assembly groove.

      B003SWEC02
      *a SST (Holder) *b SST (Guide)
      *c Gently Press *d Correct
      *e Incorrect - -
      SST
      09260-39015   ( 09268-03010, 09268-03020 )

      Note

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

    10. B003VLJC02
      *a SST (Guide)

      Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly tip side) as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the fuel injector assembly groove.

      SST
      09260-39015   ( 09268-03020 )

      Note

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      Tech Tips


      • Set SST (guide) so that its bottom surface and fuel injector seal are flush.

      • If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.

    11. B003V6OC02
      *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 fuel injector assembly grooves.

      Note

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

  2. INSTALL FUEL INJECTOR ASSEMBLY


    1. Install a new O-ring, new No. 1 back-up ring, new No. 2 back-up ring, new No. 3 back-up ring, and new E-ring to the fuel injector assembly as shown in the illustration.

      B003UVDC03
      *1 No. 1 Back-up Ring *2 No. 2 Back-up Ring
      *3 No. 3 Back-up Ring *4 O-ring
      *5 E-ring - -
      *a Alignment 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 fuel injector assembly.

      • Check that the No. 1 back-up ring and No. 2 back-up ring are installed in the correct direction.

      • Make sure that the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and O-ring are installed in the correct order.

      • Check that the alignment openings of the back-up rings are 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.

    2. Install the injector nozzle holder clamp.

    3. B003UDUC02
      *a Protrusion
      B003WAF No Gap

      Apply gasoline to the O-ring. Install the injector nozzle holder clamp by aligning the protrusion of the clamp with the notch of the No. 1 delivery pipe sub-assembly and No. 2 delivery pipe sub-assembly.

      Note


      • Make sure that there is no gap between the No. 1 delivery pipe sub-assembly, No. 2 delivery pipe sub-assembly and clamp.

      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the No. 1 delivery pipe sub-assembly and No. 2 delivery pipe sub-assembly.

      • Insert each fuel injector assembly straight into the No. 1 delivery pipe sub-assembly and No. 2 delivery pipe sub-assembly without tilting it.

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. Install a new injector vibration insulator to the cylinder head sub-assembly.

    2. Apply lubricant to the fuel injector assembly insertion holes.

    3. B003TYAC06
      *a Nut can be attached

      Insert the stud bolt into the fuel delivery pipe sub-assembly until the screw threads protrude enough so that a nut can be attached.

      Note


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

      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the fuel delivery pipe sub-assembly.

      • When inserting the fuel delivery pipe sub-assembly, push it in evenly without tilting it.

    4. B003WB3C02
      B003WAF Nut
      B003U82 Bolt
      B003WLN Front Side

      Install the fuel delivery pipe sub-assembly by uniformly tightening the 2 bolts and 2 nuts in several steps in the order shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

    5. Connect the 3 fuel injector assembly connectors and 2 wire harness clamps.

    6. B003U5DC03
      *1 Wire Harness

      Connect the fuel pressure sensor connector and wire harness clamp.

      Note


      • Make sure the wire harness of the fuel pressure sensor passes under the area (A) as shown in the illustration.

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

  4. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. Install new injector vibration insulators to the cylinder head sub-assembly.

    2. Apply lubricant to the fuel injector assembly insertion holes.

    3. B003TYAC07
      *a Nut can be attached

      Insert the stud bolt into the No. 2 fuel delivery pipe sub-assembly until the screw threads protrude enough so that a nut can be attached.

      Note


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

      • Check that there is no foreign matter or damage in the fuel injector assembly installation hole of the No. 2 fuel delivery pipe sub-assembly.

      • When inserting the No. 2 fuel delivery pipe sub-assembly, push it in evenly without tilting it.

    4. B003UJ4C02
      B003WAF Nut
      B003U82 Bolt
      B003WLN Front Side

      Install the No. 2 fuel delivery pipe sub-assembly by uniformly tightening the 2 bolts and 2 nuts in several steps in the order shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

    5. Connect the 3 fuel injector assembly connectors and 3 wire harness clamps.

  5. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Install a new O-ring, new No. 1 back-up ring, new No. 2 back-up ring, new No. 3 back-up ring and new E-ring to each end of the No. 3 fuel pipe sub-assembly as shown in the illustration.

      B003TFAC04
      *1 No. 1 Back-up Ring *2 No. 2 Back-up Ring
      *3 No. 3 Back-up Ring *4 O-ring
      *5 E-ring - -
      *a Alignment Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -

      Note


      • Check that there is no foreign matter or damage on the O-ring grooves of the No. 3 fuel pipe sub-assembly.

      • Check that the No. 1 back-up ring and No. 2 back-up ring are installed in the correct direction.

      • Make sure that the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and O-rings are installed in the correct order.

      • Check that the alignment openings of the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring are not overlapped or stretched as shown in the illustration.

      • After installing the O-rings, check that they are not contaminated with foreign matter and are not damaged.

      • Check that the ends of the No. 3 fuel pipe sub-assembly are not contaminated with foreign matter and are not damaged.

    2. B003US5C03
      *a No Gap
      B003U82 Front Side

      Apply engine oil to the installation hole of the fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly.

    3. Press the No. 3 fuel pipe sub-assembly, fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly together by hand until there is no gap between them, then install the No. 3 fuel pipe sub-assembly with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Do not install the No. 3 fuel pipe sub-assembly at an angle.

  6. INSTALL FUEL PUMP ASSEMBLY

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