FUEL INJECTOR(for Direct Injection) INSTALLATION

CAUTION / NOTICE / HINT

Note

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

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PROCEDURE


  1. INSTALL FUEL INJECTOR SEAL


    1. B006B98C01
      *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 the direct fuel injector assembly is struck, replace it with a new one.

    2. B006C1FC01
      *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
      09260-39030   ( 09261-03030 )
    3. B006AKGC03
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect

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

      SST
      09260-39030   ( 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. B006CZZC01
      *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
      09260-39030   ( 09261-03011, 09261-03030 )

      Note

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

    5. B006FILC01
      *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
      09260-39030   ( 09261-03030 )

      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. B006A3GC01
      *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.

      Tech Tips

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

  2. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

    Tech Tips

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



    1. B006CCAC01
      *1 Direct Fuel Injector Assembly
      *2 C-ring
      *3 Injector Vibration Insulator
      *a Taper

      Install 6 new injector vibration insulator and 6 new C-ring to each 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 6 new O-ring and 6 No. 1 fuel injector back-up ring to each direct fuel injector assembly as shown in the illustration.

      B006DANC01
      *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. B006G1UC01
      *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 No. 3 fuel injector back-up ring to each direct fuel injector assembly 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.

      Tech Tips

      Use the same procedure to install the other No. 3 fuel injector back-up ring.

    4. Install the 6 nozzle holder clamps to each direct fuel injector assembly.

    5. Install the No. 6 engine wire to the No. 2 fuel delivery pipe sub-assembly LH with the 2 bolts.

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

    6. Install the No. 5 engine wire to the No. 2 fuel delivery pipe sub-assembly RH with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    7. B006B1FC01
      *a Protrusion
      *b Positioning Hole
      B006AHR No Gap

      Connect the 3 connectors and, align the protrusion of the nozzle holder clamp with the positioning hole of the No. 2 fuel delivery pipe sub-assembly LH and insert the direct fuel injector assembly.

      Note


      • Make sure that there is no foreign matter or damage inside the direct fuel injector assembly installation holes (No. 2 fuel delivery pipe sub-assembly LH).

      • 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 No. 2 fuel delivery pipe sub-assembly LH. Be careful not to allow the direct fuel injector assembly to fall out of the No. 2 fuel delivery pipe sub-assembly LH.

      • Do not tilt the direct fuel injector assembly when inserting it into the No. 2 fuel delivery pipe sub-assembly LH.

      • Check that there is no gap between the No. 2 fuel delivery pipe sub-assembly LH and the nozzle holder clamp.

      • B006FEJC01
        *a QR Code
        *b Flow Classification Number

        Make sure the 3 direct fuel injector assemblies have the same flow classification number 1, 2, 3, 4, 5, 6, 7, 8 or 9 on each bank (6 direct fuel injector assemblies with the same flow classification number is also okay).

    8. B006B1FC01
      *a Protrusion
      *b Positioning Hole
      B006AHR No Gap

      Connect the 3 connectors and, align the protrusion of the nozzle holder clamp with the positioning hole of the No. 2 fuel delivery pipe sub-assembly RH and insert the direct fuel injector assembly.

      Note


      • Make sure that there is no foreign matter or damage inside the direct fuel injector assembly installation holes (No. 2 fuel delivery pipe sub-assembly RH).

      • 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 No. 2 fuel delivery pipe sub-assembly RH. Be careful not to allow the direct fuel injector assembly to fall out of the No. 2 fuel delivery pipe sub-assembly RH.

      • Do not tilt the direct fuel injector assembly when inserting it into the No. 2 fuel delivery pipe sub-assembly RH.

      • Check that there is no gap between the No. 2 fuel delivery pipe sub-assembly RH and the nozzle holder clamp.

      • B006FEJC01
        *a QR Code
        *b Flow Classification Number

        Make sure the 3 direct fuel injector assemblies have the same flow classification number 1, 2, 3, 4, 5, 6, 7, 8 or 9 on each bank (6 direct fuel injector assemblies with the same flow classification number is also okay).

  3. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY LH


    1. Apply lubricant to the direct fuel injector assembly installation holes of the cylinder head sub-assembly LH.

    2. Temporarily install the No. 2 fuel delivery pipe sub-assembly LH to the cylinder head sub-assembly LH.

      Note


      • 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.

      • Check that there is no foreign matter or damage on the direct fuel injector assembly installation holes of the cylinder head sub-assembly LH.

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

    3. Install the No. 2 fuel delivery pipe sub-assembly LH to the cylinder head sub-assembly LH with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    4. Attach the clamp and connect the No. 6 engine wire to the wire harness clamp bracket.

    5. Connect the connector to the No. 6 engine wire.

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


    1. Apply lubricant to the direct fuel injector assembly installation holes of the cylinder head sub-assembly RH.

    2. Temporarily install the No. 2 fuel delivery pipe sub-assembly RH to the cylinder head sub-assembly RH.

      Note


      • 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.

      • Check that there is no foreign matter or damage on the direct fuel injector assembly installation holes of the cylinder head sub-assembly RH.

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

    3. Install the No. 2 fuel delivery pipe sub-assembly RH to the cylinder head sub-assembly RH with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  5. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Temporarily install the No. 3 fuel pipe sub-assembly to the No. 2 fuel delivery pipe sub-assembly RH and No. 2 fuel delivery pipe sub-assembly LH.

      Note

      If the 2 union nuts cannot be fastened, loosen the bolts of the No. 2 fuel delivery pipe sub-assembly RH and No. 2 fuel delivery pipe sub-assembly LH, and then fasten both union nuts.

    2. B006G01C01
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the 2 union nuts.

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

      Tech Tips


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

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      • When using a 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)

  6. INSTALL FUEL PRESSURE SENSOR

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  7. INSTALL LOWER INTAKE MANIFOLD SUB-ASSEMBLY

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  8. INSTALL FUEL PUMP ASSEMBLY

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  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  10. INSPECT FOR FUEL LEAK

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  11. PERFORM INITIALIZATION


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