Injector ASSY (FA20 / direct fuel injection)
Components Inspection Removal / installation
FUEL
INJECTOR ASSY (FA20 / DIRECT FUEL INJECTION)
EXPLODED VIEW
REMOVAL
1. Intake manifold removal
(Refer to 
)
)
2. Fuel delivery pipe NO.2 removal
(1) Remove the fuel delivery pipe NO.2.
CAUTION:
When removing the fuel delivery pipe NO.2, pull it straight out so that the seal surface of fuel delivery pipe LH is not damaged.
3. Fuel delivery pipe removal
(1) Remove the 3 bolts.
(2) Remove the fuel delivery pipe.
4. Fuel delivery pipe (bank 2 side) removal
(1) Disconnect the two fuel injector connectors.
(2) Remove the two bolts and remove fuel delivery pipe (bank 2 side).
5. Fuel delivery pipe (bank 1 side) removal
(1) Disconnect the fuel pressure sensor connector and two fuel injector connectors.
(2) Remove the two bolts and remove fuel delivery pipe (bank 1 side).
6. Fuel injector ASSY removal
(1) Remove the fuel injector ASSY from the fuel delivery pipes (bank 2 side) and (bank 1 side).
Captions in illustration
| *1 |
Bank 2 side |
| *2 |
Bank 1 side |
CAUTION:
·If the tip of fuel injector ASSY is bumped or dropped, replace the fuel injector ASSY with a new one.
·When removing the injector, pull it straight out so that the seal surfaces of fuel delivery pipes (bank 2 side) and (bank 1 side) are not damaged.
·Identify the removed fuel injector ASSY with a tag etc. marked with the cylinder number.
·When removing the injector, pull it straight out so that the seal surfaces of fuel delivery pipes (bank 2 side) and (bank 1 side) are not damaged.
·Identify the removed fuel injector ASSY with a tag etc. marked with the cylinder number.
(2) Remove the fuel injector holder from the fuel injector ASSY.
(3) Remove the C-ring and fuel injector insulator.
Captions in illustration
| *1 |
C-ring |
| *2 |
Fuel injector insulator |
(4) Remove the back-up ring NO.1.
Captions in illustration
| *1 |
Back-up ring NO.1 |
| *2 |
Fuel injector seal |
| *3 |
Back-up ring NO.2 |
(5) Remove the fuel injector seal and back-up ring NO.2.
7. Fuel injector seal removal
(1) Hold the fuel injector seal and widen it a little.
CAUTION:
·Be careful not to hold the fuel injector seal too strongly in order to protect the injector groove from scratches.
·If the tip of fuel injector ASSY is bumped or dropped, replace the fuel injector ASSY with a new one.
·If the tip of fuel injector ASSY is bumped or dropped, replace the fuel injector ASSY with a new one.
INSTALLATION
1. Fuel injector seal installation
(1) Use the engine conditioner to remove the carbon on engine oil on the side surface and seal groove of injector shown in the figure.
Captions in illustration
| *a |
Cleaning area |
CAUTION:
·Do not clean the tip portion.
·Do not use a wire brush etc.
·If the tip of fuel injector ASSY is bumped or dropped, replace the fuel injector ASSY with a new one.
·Do not use a wire brush etc.
·If the tip of fuel injector ASSY is bumped or dropped, replace the fuel injector ASSY with a new one.
(2) Apply engine oil to the inner periphery of SST (guide) and set it on the injector so that the taper surface faces toward the tip side of injector.
SST
09260-39020
Captions in illustration
| *1 |
SST (guide) |
| *a |
Taper surface |
(3) Install a new fuel injector seal to the SST (holder).
SST
09260-39020
Captions in illustration
| *1 |
Fuel injector seal |
| *2 |
SST (holder) |
CAUTION:
When setting the fuel injector seal on the SST (holder), the seal is stretched and it is difficult to correct if the seal is set at an angle.
(4) Set the SST (holder) with the fuel injector seal to the tip of injector and push down the fuel injector seal with fingers to install it in the injector groove shown in the figure.
SST
09260-39020
Captions in illustration
| *1 |
SST (guide) |
| *2 |
SST (holder) |
CAUTION:
Make sure the fuel injector seal is completely fitted in the groove for its entire circumference.
(5) While holding the fuel injector seal (connector side) lightly with the SST (holder), pull up the SST (guide) toward the injector tip side slowly and seat the fuel injector seal in the injector groove.
SST
09260-39020
Captions in illustration
| *1 |
SST (guide) |
| *2 |
SST (holder) |
| *a |
Hold |
CAUTION:
Be careful not to pinch the fuel injector seal between the SST (guide) and injector groove. If it is pinched, replace it with a new one.
(6) Pull up the SST (guide) toward the injector tip side slowly and hold the SST for 5 sec. or more when the fuel injector seal on the connector side reaches to the straight portion of SST (guide) in order to correct the fuel injector seal.
SST
09260-39020
Captions in illustration
| *1 |
SST (guide) |
CAUTION:
Be careful not to pinch the fuel injector seal between the SST (guide) and injector groove. If it is pinched, replace it with a new one.
NOTE:
·A rough indication of the straight portion is the position where the bottom of fuel injector seal aligns with the bottom of SST (guide).
·When the SST (guide) cannot be pulled up because it is stuck, pull up it gradually by rotating the SST (guide) to the left and right slowly.
·When the SST (guide) cannot be pulled up because it is stuck, pull up it gradually by rotating the SST (guide) to the left and right slowly.
(7) After the fuel injector seal is installed, make sure that there is no scratches on the seal, crushing of the seal, or protrusion of the seal from the seal groove.
Captions in illustration
| *a |
Normal |
| *b |
Correction failure |
| *c |
Failure |
CAUTION:
When there is any scratches on the fuel injector seal, crushing of it, or protrusion of it from the seal groove, replace it with a new part.
2. Fuel injector ASSY installation
CAUTION:
If the tip of fuel injector ASSY is bumped or dropped, replace the fuel injector ASSY with a new one.
(1) Install a new back-up ring NO.2, new fuel injector seal and new back-up ring NO.1 as shown in the figure.
Captions in illustration
| *1 |
Back-up ring NO.2 |
| *2 |
Fuel injector seal |
| *3 |
Back-up ring NO.1 |
| *a |
Back-up ring gap |
| *b |
Running on |
| *c |
Widening |
CAUTION:
·There must be no foreign matter, scratches, etc. in the fuel injector seal groove of injector.
·Be careful not to mix up the directions of back-up springs NO.1 and NO.2.
·Be careful not to mix up the installation order of back-up spring and fuel injector seal.
·There must be no running on or widening of back-up ring gap portion as shown in the figure.
·After the installation, there must be no foreign matter, scratches, etc. in the fuel injector seal.
·Be careful not to mix up the directions of back-up springs NO.1 and NO.2.
·Be careful not to mix up the installation order of back-up spring and fuel injector seal.
·There must be no running on or widening of back-up ring gap portion as shown in the figure.
·After the installation, there must be no foreign matter, scratches, etc. in the fuel injector seal.
(2) Install a new fuel injector insulator and new O-ring.
Captions in illustration
| *1 |
C-ring |
| *2 |
Fuel injector insulator |
CAUTION:
Install the fuel injector insulator in the direction as shown in the figure.
(3) Install the fuel injector holder to the fuel injector ASSY.
(4) Apply new engine oil to the chamfered portions of injector insertion holes of the fuel delivery pipes (bank 2 side) and (bank 1 side).
(5) Align the protrusion of fuel injector holder to the arrest holes of fuel delivery pipes (bank 2 side) and (bank 1 side) to install the fuel injector holder.
Captions in illustration
| *a |
Protrusion portion |
| *b |
Arrest hole |
 |
There must be no gap. |
CAUTION:
·There must be no foreign matter, scratches, etc. inside the injector insertion holes of the fuel delivery pipes (bank 2 side) and (bank 1 side).
·There must be no gasoline on the fuel injector seal and inside the attachment hole.
·Insert the injector straight to the fuel delivery pipes (bank 2 side) and (bank 1 side) without tilting it.
·There must be no gap between the high pressure side fuel injector pipe and fuel injector holder.
·When replacing the fuel injector ASSY, install a new ASSY with the same flow stratified number.
·There must be no gasoline on the fuel injector seal and inside the attachment hole.
·Insert the injector straight to the fuel delivery pipes (bank 2 side) and (bank 1 side) without tilting it.
·There must be no gap between the high pressure side fuel injector pipe and fuel injector holder.
·When replacing the fuel injector ASSY, install a new ASSY with the same flow stratified number.
Captions in illustration
| *1 |
Flow stratified number |
| *2 |
QR code |
3. Fuel delivery pipe (bank 2 side) installation
(1) Install the fuel delivery pipe (bank 2 side) with the two bolts.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(2) Connect the two fuel injector connectors.
4. Fuel delivery pipe (bank 1 side) installation
(1) Install the fuel delivery pipe (bank 1 side) with the two bolts.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(2) Connect the two fuel injector connectors and fuel pressure sensor connector.
5. Fuel delivery pipe installation
(1) Temporarily install a new fuel delivery pipe.
(2) Temporarily install the fuel delivery pipe with the three bolts.
(3) Tighten the three bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
(4) Tighten the fuel delivery pipe.
Standard value:
Standard value:
Tightening torque=35N·m
{
357kgf·cm}
{25.8ft·lbf}
6. Fuel delivery pipe NO.2 installation
(1) Temporarily install a new fuel delivery pipe NO.2.
(2) Tighten the fuel delivery pipe NO.2.
Standard value:
Standard value:
Tightening torque=35N·m
{
357kgf·cm}
{25.8ft·lbf}
7. Intake manifold installation
(Refer to )
)UNIT INSPECTION
1. Fuel injector ASSY check
CAUTION:
This procedure must be used only when judging short circuit and open circuit. It cannot be used for judging defective operation.