FUEL INJECTOR INSTALLATION
PROCEDURE
INSTALL FUEL INJECTOR SEAL
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*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.
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*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.
09260-39021
09261-03020
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*1
Fuel Injector Seal
*a
SST (Holder)
*b
Correct
*c
Incorrect
Install a new fuel injector seal to SST (holder).
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.
-
*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.
09260-39021
09261-03011
09261-03020
Tip:Check that the fuel injector seal is seated in the fuel injector assembly groove as shown in the illustration.
-
*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.
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.
Tip: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.
-
*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.
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INSTALL FUEL INJECTOR ASSEMBLY
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*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 the 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.
Install a new O-ring and a new No. 1 fuel injector back-up ring to the fuel injector assembly as shown in the illustration.
*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
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-
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.
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*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 the 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.
Install the nozzle holder clamp to each fuel injector assembly.
-
*a
Protrusion
*b
Positioning Hole
No Gap
Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe 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).
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. Be careful not to allow the fuel injector assembly to fall out of the fuel delivery pipe.
Do not tilt the fuel injector assembly when inserting it into the fuel delivery pipe.
*1
O-Ring
*2
Fuel Delivery Pipe
*a
Correct
*b
Incorrect
Check that there is no gap between the fuel delivery pipe and the nozzle holder clamp.
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*a
QR Code
*b
Flow Classification Number
Make sure the 4 fuel injector assemblies have the same flow classification number 1, 2 or 3 (the number to the left of the QR code).
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INSTALL FUEL DELIVERY PIPE
for 3 Bolts Type:
Apply lubricant to the fuel injector assembly installation holes of the cylinder head sub-assembly.
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*a
Protruding enough to install nut
Temporarily install the fuel delivery pipe 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, push it in evenly without tilting it.
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Bolt
Nut
Install the fuel delivery pipe by uniformly tightening the 3 bolts and 2 nuts in the order shown in the illustration.
29 N*m
296 kgf*cm
21 ft.*lbf
for 5 Bolts Type:
Apply lubricant to the fuel injector assembly installation holes of the cylinder head sub-assembly.
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Temporarily install the fuel delivery pipe to the cylinder head sub-assembly with the 2 bolts.
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, push it in evenly without tilting it.
Tip:
*a
2 to 3 threads
Install the 2 bolts by 2 to 3 threads.
-
*a
No Gap
Push
Push the fuel delivery pipe until it contacts the cylinder head sub-assembly.
Note:Make sure that there is no gap between the fuel delivery pipe and cylinder head sub-assembly.
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Install the fuel delivery pipe by uniformly tightening the 5 bolts in the order shown in the illustration.
29 N*m
296 kgf*cm
21 ft.*lbf
CONNECT NO. 4 ENGINE WIRE
Connect the 4 fuel injector assembly connectors.
Connect the fuel pressure sensor connector.
TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
INSTALL FUEL PUMP ASSEMBLY
INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
INSTALL INTAKE MANIFOLD
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note:When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
INSPECT FOR FUEL LEAK
PERFORM INITIALIZATION
Perform "Inspection After Repair" after replacing a fuel injector assembly.