Attention:
- When carrying out work in the service station premises, hang up a sign saying "FIRE HAZARD".
- Carry out work in a well-ventilated area. Have a CO₂ fire extinguisher at hand.
- Do not smoke when servicing the fuel system. Do not light a flame or create sparks.
Removal
1. Relieve the fuel pressure. See chapter Engine management system.
2. Remove the upper part of the intake manifold. See section "Upper part of the intake manifold".
3. Disconnect the quick release fitting as follows.
Disconnect the fuel hose from the fuel pipe.
- a. Pull straight and remove the quick release fitting from the fuel line.
- b. Remove the fuel hose from the clamp on the bracket.
- c. Place the puller on the fuel line with the sleeve facing the quick release fitting.
- d. Insert the puller into the quick-release fitting until the sleeve rests against it. Fix the puller in this position.
Caution: The quick-release fitting will not come off if you force the puller into the fitting. Secure the puller in a position where it rests against the fitting.
Note: This model is not equipped with a fuel drainage system.
- e. Pull straight and remove the quick release fitting from the fuel line.
Attention:
- Pull the quick release fitting while holding section "A" as shown in the figure.
- Do not pull sideways. This may damage the O-ring inside the quick release fitting.
- Since fuel will spill, stock up on a container and a rag in advance.
- Do not light a fire or create sparks.
- Keep components away from heat sources. Be especially careful when welding.
- Do not expose components to battery electrolyte or other acids.
- When removing/installing, do not bend or twist the section between the quick release fitting and the fuel hose.
- To keep the connection area clean and to prevent damage and foreign particles from entering, plug the openings of the disconnected tubes with plugs or cover them with plastic bags.
4. Disconnect the connectors from the fuel injectors.
5. Remove the protective cover from the fuel pipe.
Loosen the bolts in the reverse order shown in the illustration.
6. Remove the fuel injectors and fuel pipe assembly.
Loosen the bolts in the reverse order shown in the illustration.
Attention:
- Make sure the fuel injector nozzle does not come into contact with other components.
- Collect any remaining fuel that has spilled from the tubes with a napkin.
7. Remove the fuel injector (3) from the fuel pipe (1) by performing the following operations:
- a. Release the clamp (2) and remove it.
- b. Remove the fuel injectors from the fuel pipe at a right angle.
Attention:
- Do not spill any remaining fuel from the fuel pipe.
- Do not damage the injector nozzle.
- Do not drop or hit fuel injectors.
- Do not disassemble fuel injectors.
Installation
1. When installing new O-rings into the fuel injector, observe the following:
Attention:
- The upper and lower O-rings are different. Do not confuse them.
- Fuel pipe side: black
- From the side it will spray, nozzles: green
Handle the O-rings with bare hands. (Do not wear gloves). Lubricate the O-rings with engine oil. Do not clean O-rings with solvent. Make sure there are no foreign particles on the O-ring or sealing surface. When installing, do not scratch the seals with a tool or fingernails. Also, do not twist or stretch the O-rings. If the O-ring is stretched during installation, do not insert it into the fuel pipe immediately. Insert the O-ring into the fuel pipe at a right angle. Do not move or twist it.
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2. Insert the fuel injector (4) into the fuel pipe (1) as follows:
- a. Insert the clamp (2) into the groove on the fuel injector.
Insert the clamp so that the tab (F) on the fuel injector aligns with the notch (D) on the clamp.
Attention:
- Always replace the clamps with new ones.
- Position the clamp so that it does not touch the O-ring. Otherwise, replace the O-ring.
- b. Insert the fuel injector into the fuel pipe with the clamp attached. Insert it while maintaining the centering.
Insert the fuel injector so that the protrusion (B) of the fuel tube fits into the notch (C) on the clamp.
Make sure that the flange (A) of the fuel pipe is securely fixed in the installation groove (E) on the clamp.
- c. Check for proper installation by making sure the fuel injector does not rotate or come off.
3. Install the fuel pipe and fuel injectors assembly onto the cylinder head.
3. O-ring (blacker)
5. O-ring (green)
Tighten the mounting bolts in two passes in the order shown by the numbers in the illustration.
Caution: Do not allow the fuel injector nozzle tip to come into contact with other components.
4. Install the protective cover on the fuel pipe.
Tighten the mounting bolts in two passes in the order shown by the numbers in the illustration.
5. Connect the wiring to the fuel injector.
6. Connect the fuel hose as follows:
- a. Make sure there is no damage or foreign matter deposits inside and around the fuel line and quick release fitting.
- b.Apply a thin coat of fresh engine oil to the tip of the fuel line.
- c. Align the centers and insert the quick-release fitting into the fuel line without distorting it.
Insert the quick release fitting into the fuel line until the first flange on the fuel line is fully seated in the quick release fitting and the second flange is positioned under the bottom edge of the quick release fitting.
Attention:
- When inserting the fuel pipe into the quick release fitting, hold it by section "A" as shown in the figure.
- To avoid damaging the O-ring inside the quick release fitting due to crooked installation, align the centers precisely.
- Insert until you hear a click and feel actual engagement.
- To avoid confusing engagement with a similar sound, perform the following operation.
- d. Before securing the fuel pipe with the clamp, pull the quick release fitting holding the section "A" to make sure it is fully engaged (connected) so that it does not slip off the fuel line.
- e. Install the cap onto the quick release fitting.
Install the cap on the quick-release fitting with the arrow pointing towards the quick-release fitting (side of the fuel hose).
Attention:
- Make sure the quick release fitting and fuel line are securely engaged with the mounting groove on the quick release fitting cap.
- If the cap is difficult to install on the quick-release fitting, the quick-release fitting may not be installed correctly. Check again for proper connection.
- f. Secure the fuel hose with a clamp.
7. After this operation, installation is carried out in the reverse order of removal.
Post-installation check
Checking for fuel leaks
1. Create pressure in the fuel lines by turning the ignition key to the "ON" position (without starting the engine). Then check for fuel leaks at the joints.
Note: Use mirrors to check in hard to reach places.
2. Start the engine. Increase the engine speed and check again for fuel leaks at the fuel line joints.
Caution: Do not touch the engine immediately after stopping, as it becomes very hot.