Fuel Injector: Service and Repair

REPLACEMENT (From July 2003)

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
3. REMOVE ENGINE COVER SUB-ASSY NO.1
4. DISCONNECT FUEL TUBE SUB-ASSY
5. REMOVE FUEL DELIVERY PIPE W/INJECTOR

NOTE: Be careful not to drop the injectors when removing the delivery pipe.




a. Remove the ventilation hose No. 2.
b. Disconnect the 4 injector connecters from the injector.
c. Remove the 2 clamps and wire harnesses from the delivery pipe.
d. Remove the 2 bolts and the delivery pipe together with the 4 injectors.
e. Remove the 2 spacers from the cylinder head.

6. REMOVE FUEL INJECTOR ASSY
a. Pull out the 4 injectors from the delivery pipe.




7. INSTALL FUEL INJECTOR ASSY
a. Install a new insulator to each injector.
b. Apply a light coat of grease or gasoline to a new O-ring and install to each injector.




c. Apply a light coat of grease or gasoline on the place where a delivery pipe touches the O-ring.
d. To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth.
e. Install the 4 injectors.

NOTE:
- Be careful not to twist the O-ring.
- After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.

f. Position the injector connector downward.

8. INSTALL FUEL DELIVERY PIPE W/INJECTOR




a. Place the 2 spacers in position on the cylinder head.
b. Place the delivery pipe together with the 4 injectors in position on the cylinder head.




c. Temporarily install the 2 bolts holding the delivery pipe to the cylinder.

NOTE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.

d. Position the injector connector outward.
e. Tighten the 2 bolts holding the delivery pipe to the cylinder head.

Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)

9. CONNECT FUEL TUBE SUB-ASSY
10. INSPECT FOR FUEL LEAKS
11. INSTALL ENGINE COVER SUB-ASSY NO.1
12. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE