Fuel Injector: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ PERFORMANCE ROD)
a. Remove the 2 nuts and upper brace.
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
a. Disconnect the MAF meter connector (*1).
b. Disconnect the 4 vacuum hoses (*2).
c. Disconnect the ventilation hose No. 2 (*3).
d. Remove the fuel vapor feed hose from the 2 hose clamps (*4).
e. Loosen the 2 air cleaner cap bolts (*5).
f. Loosen the air cleaner hose clamp bolt, and remove the air cleaner cap (*6).
g. Remove the air cleaner filter element.
6. REMOVE EMISSION CONTROL VALVE SET
a. Disconnect the 2 VSV connectors (*1).
b. Remove the wire harness clamp (*2).
c. Disconnect the fuel vapor feed hose No. 1 (*3).
d. Disconnect the fuel vapor feed hose No. 2 (*4).
e. Disconnect the 2 vacuum hoses (*5).
f. Remove the clamp (*6).
g. Remove the 2 nuts and the emission control valve set.
7. REMOVE INTAKE AIR SURGE TANK
a. Disconnect the throttle motor connector (*1).
b. Disconnect the water by-pass hose No. 3 (*2).
c. Disconnect the water by-pass hose No. 2 (*3).
d. Disconnect the union to check valve hose (*4).
e. Disconnect the ventilation hose.
f. Remove the 2 nuts and disconnect the pressure feed tube.
g. Remove the 2 bolts and engine hunger No. 1 (*1).
h. Remove the 2 bolts and surge tank stay No. 1 (*2).
i Remove the 2 bolts and surge tank stay No. 2 (*3).
j. Using an 8 mm socket hexagon wrench, remove the 4 bolts.
k. Remove the 2 nuts, emission control valve bracket and intake air surge tank.
l. Remove the gasket from the intake air surge tank.
8. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
a. Remove the bolt and disconnect the No. 1 fuel pipe (*1).
b. Remove the fuel pressure pulsation damper and 2 gaskets (*2).
c. Remove the fuel pipe No. 2 union bolt and 2 gaskets (*3).
9. REMOVE FUEL INJECTOR ASSEMBLY
a. Disconnect the 6 fuel injector connectors.
b. Remove the 4 bolts and 2 fuel delivery pipes together with the 6 fuel injectors.
NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
c. Remove the 4 delivery pipe No. 1 spacers (A) and 6 insulators (B) from the intake manifold.
d. Pull out the fuel injector from the fuel delivery pipe.
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
a. Install a new grommet to the injector.
b. Apply a light coat of grease or gasoline to a new O-ring, and install it to the injector.
c. Apply a light coat of grease or gasoline on the place where the fuel delivery pipe contacts the O-ring.
d. Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
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.
e. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
f. Place the 2 fuel delivery pipes and the 6 fuel injectors together on the intake manifold.
NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
g. Temporarily install the 4 bolts which are used to attach the fuel delivery pipe to the intake manifold.
NOTE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
h. Tighten the 4 bolts.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
i. Connect the 6 fuel injector connectors.
2. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
a. Install 2 new gaskets and the fuel pipe No. 2 union bolt.
Torque: 33 N.m (337 kgf.cm, 24 ft.lbf)
b. Install 2 new gaskets and the fuel pressure pulsation damper.
Torque: 33 N.m (337 kgf.cm, 24 ft.lbf)
c. Install the No. 1 fuel pipe with the bolt.
Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
3. INSTALL INTAKE AIR SURGE TANK
a. Install a new gasket to the intake air surge tank.
b. Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
c. Using an 8 mm socket hexagon wrench, tighten the 4 bolts.
Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
d. Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
e. Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
f. Install the engine hunger No. 1 with the 2 bolts.
Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
g. Install the pressure feed tube with the 3 nuts.
Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
h. Connect the ventilation hose.
i. Connect the union to check valve hose.
j. Connect the water by-pass hose No. 2.
k. Connect the water by-pass hose No. 3.
i. Connect the throttle motor connector.
4. INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
6. CHECK CONNECTION OF VACUUM HOSE
7. ADD ENGINE COOLANT
8. INSPECT FOR COOLANT LEAK
9. INSPECT FOR FUEL LEAK
10. INSTALL V-BANK COVER SUB-ASSEMBLY
11. INSTALL FRONT SUSPENSION UPPER BRACE CENTER
a. Install the upper brace with the 2 nuts.
Torque: 80 N.m (815 kgf.cm, 59 ft.lbf)