Attention:
- When carrying out work in the service station room, hang a sign «FLAMMABLE».
- Work in a well ventilated area. Have a CO2 fire extinguisher handy.
- Do not smoke while servicing the fuel system. Do not light fire or produce sparks.
Removing
1. Relieve fuel pressure. See chapter Engine management system.
2. Remove the upper part of the intake manifold. See section «upper intake manifold».
3. Disconnect the quick fitting as follows.
Disconnect the fuel hose from the fuel pipe.
- A. Pull in a straight line and remove the quick-release fitting from the fuel pipe.
- b. Remove the fuel hose from the clamp on the bracket.
- c. Put the puller on the fuel pipe with the sleeve towards 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.
Attention: The quick-release fitting will not come off if you force the puller into place. Lock the puller in a position where it rests on the fitting.
Note: The fuel extraction system is not provided on this model.
- e. Pull in a straight line and remove the quick fitting from the fuel pipe.
Attention:
- Pull on the quick-release fitting while holding the area «A», as it shown on the picture.
- Don't pull to the side. Otherwise, the O-ring inside the quick fitting can be damaged.
- Since fuel will spill, stock up on a container and a rag in advance.
- Do not light fire or produce sparks.
- Keep components away from heat sources. Be especially careful when performing welding work.
- Do not expose components to battery electrolyte or other acids.
- When removing/installing, do not bend or twist the area between the quick-release fitting and the fuel hose.
- To keep the connection area clean and to prevent damage and ingress of foreign particles, plug the openings of the disconnected pipes with plugs or cover with plastic bags.
4. Disconnect connectors from fuel injectors.
5. Remove the protective trim from the fuel tube.
Loosen the bolts in the reverse order shown in the figure.
6. Remove the fuel injectors and fuel tube assembly.
Loosen the bolts in the reverse order shown in the figure.
Attention:
- Make sure the fuel injector nozzle does not come into contact with other components.
- Collect the remains of the fuel spilled from the tubes with a napkin.
7. Remove fuel injector (3) from the fuel pipe (1), by doing the following:
- A. Release the clamp (2) and take it off.
- b. Remove the fuel injectors from the fuel tube 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 the fuel injectors.
- Do not disassemble fuel injectors.
Installation
1. When installing new O-rings in the fuel injector, observe the following:
Attention:
- The top and bottom O-rings are different. Don't mix them up.
- Fuel pipe side: black
- From the side spray, nozzles: green
Handle O-rings with bare hands. (Don't wear gloves). Lubricate the O-rings with engine oil. Do not clean O-rings with solvent. Make sure that there are no foreign particles on the O-ring and on the 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 immediately insert it into the fuel pipe. Insert the O-ring into the fuel pipe at a right angle. Do not move or twist it.
2. Insert fuel injector (4) into the fuel line (1) in the following way:
- A. Insert clip (2) into the groove on the fuel injector.
Insert the clamp so that the protrusion (F) on the fuel injector is aligned with the cutout (D) on the clamp.
Attention:
- Always replace clamps with new ones.
- Position the clamp so that it does not interfere with the O-ring. Otherwise, replace the O-ring.
- b. Insert the fuel injector into the fuel tube with the clamp attached. Insert it while maintaining centering.
Insert the fuel injector so that the protrusion (IN) fuel pipe went into the cutout (WITH) on the clamp.
Make sure the flange (A) the fuel pipe is securely fixed in the mounting groove (E) on the clamp.
- With. Check for proper installation by making sure the fuel injector does not spin or pop off.
3. Install the fuel pipe and fuel injector assemblies to the cylinder head.
3. O-ring (blacker)
5. O-ring (green)
Tighten the mounting bolts in two passes in the order indicated by the numbers in the figure.
Caution: Do not allow fuel injector nozzle tip to come into contact with other components.
4. Install the protective cap on the fuel tube.
Tighten the mounting bolts in two passes in the order indicated by the numbers in the figure.
5. Connect electrical wiring to fuel injector.
6. Connect the fuel hose as follows:
- A. Check that there is no damage or foreign matter in or around the fuel pipe and quick fitting.
- b. Apply a thin layer of fresh engine oil to the tip of the fuel pipe.
- With. Align the centers and insert the quick fitting into the fuel tube without distortion.
Insert the quick fitting into the fuel tube until the first collar on the fuel tube is fully engaged with the quick fitting and the second collar is under the lower edge of the quick fitting.
Attention:
- When inserting the fuel pipe into the quick-release fitting, hold it by the section «A», as it shown on the picture.
- To avoid damage to the O-ring inside the quick fitting due to misalignment, align the centers exactly.
- Insert until you hear a click and feel the actual engagement.
- In order not to confuse engagement with a similar sound, perform the following operation.
- d. Before securing the fuel pipe with a clamp, pull on the quick-release fitting while holding the section «A». Make sure it is fully engaged (connected) so that it does not come off the fuel pipe.
- e. Install the cap on the quick fitting.
Install the cap on the quick fitting with the arrow pointing towards the quick fitting (fuel hose side).
Attention:
- Make sure the quick fitting and fuel pipe are securely engaged in the groove on the quick fitting cap.
- If the cap is difficult to fit onto the quick fitting, the quick fitting may not be installed correctly. Check the connection again.
- f. Secure the fuel hose with a clamp.
7. After this operation, installation is carried out in the reverse order of removal.
Check after installation
Checking for fuel leaks
1. Pressurize the fuel lines by turning the ignition key to the «ON» (without starting the engine). Then check for fuel leaks at the joints.
Note: Use a mirror to check in hard-to-reach places.
2. Start the engine. While increasing the engine speed, check again for fuel leaks at the fuel line joints.
Caution: Do not touch the engine immediately after stopping as it gets very hot.