FUEL INJECTOR(for Direct Injection) REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during direct fuel injector assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Battery terminal is disconnected/reconnected	Memorize steering angle neutral point	LKA/LDA system	Click here
		Parking support brake system*
		Pre-collision system
		Adaptive high beam system
		Lighting system (EXT) Cornering lights
		Variable gear ratio steering system	Click here
		Parking assist monitor system	Click here
		Panoramic view monitor system	Click here
	Initialize rear door sunshade system	Rear door sunshade system	Click here
	Initialize power trunk lid system	Power trunk lid system	Click here
Replacement of direct fuel injector assembly	Inspection After Repair	Poor idle, etc. Engine start function, etc.	w/ Canister Pump Module: Click here w/o Canister Pump Module: Click here

*: When performing learning using the GTS.
Click here Click here

CAUTION:

Never perform work on fuel system components near any possible ignition sources.
Vaporized fuel could ignite, resulting in a serious accident.

Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

Note

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

DISCHARGE FUEL SYSTEM PRESSURE

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PRECAUTION

Note

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Note

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

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REMOVE FUEL PUMP ASSEMBLY

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REMOVE FUEL PRESSURE SENSOR

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REMOVE LOWER INTAKE MANIFOLD SUB-ASSEMBLY

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REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY
1. Using a 17 mm union nut wrench, loosen the 2 union nuts and remove the No. 3 fuel pipe sub-assembly from the No. 2 fuel delivery pipe sub-assembly RH and No. 2 fuel delivery pipe sub-assembly LH.
REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY RH
1. Remove the 4 bolts and No. 2 fuel delivery pipe sub-assembly RH from the cylinder head sub-assembly RH.
  
  Note
  
  Do not strike the tips of the direct fuel injector assembly.
REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY LH
1. Disconnect the connector from the No. 6 engine wire.
2. Detach the clamp and disconnect the No. 6 engine wire from the wire harness clamp bracket.
3. Remove the 4 bolts and No. 2 fuel delivery pipe sub-assembly LH from the cylinder head sub-assembly LH.
  
  Note
  
  Do not strike the tips of the direct fuel injector assembly.
REMOVE DIRECT FUEL INJECTOR ASSEMBLY
Note

Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.
1. Fix the No. 2 fuel delivery pipe sub-assembly RH in a vise between aluminum plates.
  Note
  - Do not tighten the vise more than necessary.
  - Do not damage the direct fuel injector assembly.
2. Disconnect the 3 connectors and 3 direct fuel injector assemblies from the No. 2 fuel delivery pipe sub-assembly RH.
  Note
  
  Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the No. 2 fuel delivery pipe sub-assembly RH O-ring.
  
  After removing the direct fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the No. 2 fuel delivery pipe sub-assembly RH side.
  
  Cover each tip of the direct fuel injector assembly to prevent it from being damaged.
3. Disconnect the 3 connectors and 3 direct fuel injector assemblies from the No. 2 fuel delivery pipe sub-assembly LH.
  Note
  
  Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the No. 2 fuel delivery pipe sub-assembly LH O-ring.
  
  After removing the direct fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the No. 2 fuel delivery pipe sub-assembly LH side.
  
  Cover each tip of the direct fuel injector assembly to prevent it from being damaged.
4. Remove the 2 bolts and No. 5 engine wire from the No. 2 fuel delivery pipe sub-assembly LH.
5. Remove the 2 bolts and No. 6 engine wire from the No. 2 fuel delivery pipe sub-assembly RH.
6. Remove the 6 nozzle holder clamps from the direct fuel injector assembly.
7. Using needle nose pliers, remove the 6 No. 3 fuel injector back-up rings from each direct fuel injector assembly.
  
  Note
  
  Do not damage the area that contacts the O-ring.
8. Remove the 6 O-rings and 6 No. 1 fuel injector back-up rings from each direct fuel injector assembly.
9. Remove the 6 C-rings and 6 injector vibration insulators from each direct fuel injector assembly.
REMOVE FUEL INJECTOR SEAL
1. Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.
  Note
  
  Excessively pinching the fuel injector seal may damage the groove of the direct fuel injector assembly.
  
  If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.
2. Remove the 6 fuel injector seal from each direct fuel injector assembly.