FUEL INJECTOR INSTALLATION


  1. INSTALL FUEL INJECTOR SEAL


    1. A01FGI9E02
      Text in Illustration
      *1 Clean Area

      Apply engine conditioner to the injector area shown in the illustration. Using a piece of cloth, clean carbon deposits from the injector and its grooves.

      Note


      • Do not clean the tip of the injector.

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

      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

    2. A01FGCVE01
      Text in Illustration
      *1 SST (Guide)
      *2 Tapered Inner Portion

      Apply engine oil to the injector contact surface of SST (guide). Then attach SST (guide) to the injector with the tapered inner portion facing the tip of the injector, as shown in the illustration.

      SST
      09260-39015   ( 09268-03020 )
    3. A01FGUIE07
      Text in Illustration
      *1 Fuel Injector Seal
      *2 SST (Holder)
      *a CORRECT
      *b INCORRECT

      Install a new injector seal to SST (holder).

      SST
      09260-39015   ( 09268-03010 )

      Note

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

    4. A01FGKZE03
      Text in Illustration
      *1 SST (Holder)
      *2 SST (Guide)

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

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

      Tech Tips

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

    5. A01FGO8E09
      Text in Illustration
      *1 SST (Holder)
      *2 SST (Guide)
      *3 Injector Seal
      *a Gently Press
      *b Slowly Slide
      *c CORRECT
      *d INCORRECT

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

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

      Note

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

      Tech Tips


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

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

    6. A01FGUIE07
      Text in Illustration
      *1 Fuel Injector Seal
      *2 SST (Holder)
      *a CORRECT
      *b INCORRECT

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

      SST
      09260-39015   ( 09268-03010 )
    7. A01FDT0E01
      Text in Illustration
      *1 SST (Holder)
      *2 SST (Guide)
      *3 Welded Groove
      *4 Injector Seal

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

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

      Note

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

    8. A01FIQVE03
      Text in Illustration
      *1 SST (Guide)
      *2 Injector Seal

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

      SST
      09260-39015   ( 09268-03020 )

      Note

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

      Tech Tips


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

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

    9. A01FF8XE03
      Text in Illustration
      *1 SST (Holder)
      *2 SST (Guide)
      *3 Injector Seal
      *a Gently Press
      *b Slide
      *c CORRECT
      *d INCORRECT

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

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

      Note

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

    10. A01FGZFE03
      Text in Illustration
      *1 SST (Guide)
      *2 Injector Seal

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

      SST
      09260-39015   ( 09268-03020 )

      Note

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

      Tech Tips


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

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

    11. A01FJ3RE05
      Text in Illustration
      *a Normal
      *b Protruding
      *c Deformed
      *d CORRECT
      *e INCORRECT

      After installing the seals, check that they are not scratched, deformed or protruding from the injector groove.

      Note

      If a 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 backup rings (No. 1, No. 2 and No. 3) and new E-ring to the fuel injector as shown in the illustration.

      A01FF2BE07
      Text in Illustration
      *1 No. 1 Backup Ring *2 No. 2 Backup Ring
      *3 No. 3 Backup 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 damaged areas in the O-ring groove of the injector.

      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.

      • Make sure that the backup rings and O-ring are installed in the correct order.

      • Check that the alignment openings of the backup 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. A01FDK4

      Apply gasoline to the O-ring. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.

      Note


      • Make sure that there is no gap between the delivery pipe and clamp.

      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.

      • Insert the injector straight into the delivery pipe without tilting it.

  3. INSTALL NO. 1 FUEL DELIVERY PIPE SUB-ASSEMBLY


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

    2. Apply lubricant to the installation hole of the injector.

    3. A01FFGLE08
      Text in Illustration
      *a Nut can be attached

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

      Note


      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.

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

    4. A01FFQGE03
      Text in Illustration
      *1 Nut
      *2 Bolt
      *a Front

      Install the No. 1 fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    5. Connect the 3 injector connectors and 2 wire harness clamps.

    6. A01FH9EE01
      Text in Illustration
      *1 Wire Harness

      Connect the fuel pressure sensor connector and attach the clamp.

      Note


      • Make sure the wire harness of the fuel pressure sensor passes under the area labeled 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.

    2. Apply lubricant to the installation holes of the injectors.

    3. A01FFGLE08
      Text in Illustration
      *a Nut can be attached

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

      Note


      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.

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

    4. A01FHO7E05
      Text in Illustration
      *1 Nut
      *2 Bolt
      *a Front

      Install the No. 2 fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    5. Connect the 3 injector connectors and 3 wire harness clamps.

  5. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Install new O-rings, new backup rings (No. 1, No. 2 and No. 3) and new E-rings to the No. 3 fuel pipe as shown in the illustration.

      A01FISME07
      Text in Illustration
      *1 No. 1 Backup Ring *2 No. 2 Backup Ring
      *3 O-Ring *4 No. 3 Backup Ring
      *5 E-Ring - -
      *a Alignment Opening *b Overlapped
      *c Stretched *d CORRECT
      *e INCORRECT - -

      Note


      • Check that there is no foreign matter or damaged areas in the O-ring groove of the injector.

      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.

      • Make sure that the backup rings and O-ring are installed in the correct order.

      • Check that the alignment openings of the backup 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.

      • Check that the fuel pipe installation end is not contaminated with foreign matter and is not damaged.

    2. A01FHZ8E01
      Text in Illustration
      *a No Gap
      A01FJ4N Front

      Apply gasoline to the O-ring.

    3. Press the fuel pipe and delivery pipe together by hand until there is no gap between them. Then install the No. 3 fuel pipe with the 4 bolts.

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

      Note

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

  6. INSTALL FUEL PUMP ASSEMBLY

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