FUEL INJECTOR(for Direct Injection) INSTALLATION

PROCEDURE


  1. INSTALL FUEL INJECTOR SEAL


    1. B003U3GC01
      *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 the fuel injector assembly is struck, replace it with a new one.

    2. B003TEHC01
      *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
      09260-39021   ( 09261-03020 )
    3. B003WVIC03
      *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. B003VI3C01
      *a SST (Holder)
      *b SST (Guide)

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

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

      Tech Tips

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

    5. B003X4FC01
      *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 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
      09260-39021   ( 09261-03020 )

      Note

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

    6. B003VX1C03
      *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 groove.

      Note

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

      Tech Tips

      Use the same procedure to install the other fuel injector seals.

  2. INSTALL FUEL INJECTOR ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing a fuel injector assembly.

    Click here


    1. B003UL3C01
      *1 Fuel Injector Assembly
      *2 C-ring
      *3 Injector Vibration Insulator
      *a Taper

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

      Note


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

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

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

      B003TL1C01
      *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 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. B003WZUC03
      *1 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 each 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 fuel injector assembly.

    5. B003U30C01
      *a Protrusion
      *b Positioning Hole
      B003WAF No Gap

      Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, and insert the fuel injector assembly.

      Note


      • Make sure that there is no foreign matter or damage inside the fuel injector assembly installation holes (fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH).

      • Do not allow gasoline to get on the O-rings or inside the installation holes.

      • If it is difficult to insert the fuel injector assembly, apply new engine oil to the chamfer of the fuel injector assembly installation hole of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH. Be careful not to allow the fuel injector assembly to fall out of the fuel delivery pipe with sensor assembly LH or fuel delivery pipe RH.

      • Do not tilt the fuel injector assembly when inserting it into the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.

      • Check that there is no gap between the fuel delivery pipe with sensor assembly LH, fuel delivery pipe RH and the nozzle holder clamp.

      • B003WFIC01
        *a QR Code
        *b Flow Classification Number

        Make sure the 3 fuel injector assemblies of each bank all have the same flow classification number and that the flow classification number is 6, 7 or 8 (it is acceptable for both banks to have a different flow classification number).

  3. INSTALL FUEL DELIVERY PIPE RH


    1. Connect the 3 fuel injector assembly connectors and install the No. 6 engine wire.

    2. Apply lubricant to the fuel injector assembly installation holes of the cylinder head sub-assembly.

    3. B003VO8C01
      *a Protruding enough to install nut

      Temporarily install the fuel delivery pipe RH so that the stud bolts protrude enough to install the nuts.

      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 cylinder head sub-assembly.

      • When installing the fuel delivery pipe RH, push it in evenly without tilting it.

    4. B003W18C02
      B003WAF Bolt
      B003U82 Nut
      B003WLN Front

      Install the fuel delivery pipe RH by uniformly tightening the 2 bolts and 2 nuts in the order shown in the illustration.

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

    5. Engage the clamp to connect the No. 6 engine wire to the fuel delivery pipe RH.

    6. Install the bolt.

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

  4. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

    Note


    • Do not remove the fuel pressure sensor from the fuel delivery pipe with sensor assembly LH.

    • If the fuel pressure sensor is removed, replace the fuel pressure sensor (fuel delivery pipe with sensor assembly LH) with a new one.


    1. Connect the 3 fuel injector assembly connectors and install the No. 7 engine wire.

    2. Apply lubricant to the fuel injector assembly installation holes of the cylinder head LH.

    3. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the cylinder head LH.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. B003VO8C01
      *a Protruding enough to install nut

      Temporarily install the fuel delivery pipe with sensor assembly LH so that the stud bolts protrude enough to install the nuts.

      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 cylinder head LH.

      • When installing the fuel delivery pipe with sensor assembly LH, push it in evenly without tilting it.

    5. B003W88C02
      B003WAF Bolt
      B003U82 Nut
      B003WLN Front

      Install the fuel delivery pipe with sensor assembly LH by uniformly tightening the 2 bolts and 2 nuts in the order shown in the illustration.

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

    6. Engage the clamp to connect the No. 7 engine wire to the fuel delivery pipe with sensor assembly LH.

    7. Install the bolt.

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

    8. Connect the fuel pressure sensor connector.

  5. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Temporarily install the No. 2 fuel pipe sub-assembly to the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH and tighten the 2 union nuts by hand.

    2. B003V04C01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length
      B003U82 Front

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

      Torque:
      Specified tightening torque
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note


      • If the 2 union nuts cannot be fastened, loosen the nuts of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, and then fasten both union nuts.

      • Do not adjust the torque in the loosening direction.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

      • Install the union nut wrench parallel with the torque wrench.

  6. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

    Click here

  7. PERFORM INITIALIZATION


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

      Click here