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Removal and Installation
warning
  • Put a “CAUTION: FLAMMABLE” sign in the workshop.
  • Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
  • Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
 
 
REMOVAL
 
 
1. Release the fuel pressure. Refer to Work ProcedureWork Flow.
2. Disconnect the battery negative terminal. Refer to Removal and Installation.
3. Remove intake manifold. Refer to Removal and Installation.
4. Remove high pressure fuel rail protector.
5. Remove high pressure fuel rail insulator.
6. Remove high pressure fuel tube. Refer to Removal and Installation.Removal and Installation
7. Disconnect harness connector from fuel rail pressure sensor.
8. Disconnect harness connector from fuel injector.
9. Remove fuel rail pressure sensor if necessary.
10. Remove high pressure fuel rail and fuel injector assembly.
  • Loosen mounting bolts and nuts in the reverse order of as shown in the figure.
caution
  • When removing, be careful to avoid any interference with fuel injector.
  • Use a shop cloth to absorb any fuel leakage from high pressure fuel rail.
11. Remove fuel injector from high pressure fuel rail with the following procedure:
  1. Remove fuel injector from high pressure fuel rail by pulling straight.
    caution
    • Be careful with remaining fuel that may go out from fuel tube.
    • Be careful not to damage fuel injector nozzle during removal.
    • Never bump or drop fuel injector.
    • Never disassemble fuel injector.
  2. Open and remove clip if necessary.
  3. Remove O-ring, backup ring and injector holder from direct fuel injector.
    cautionDo not reuse O-ring, backup ring or injector holder.
  4. Cut seal ring while pinching it.
    caution
    • Do not scratch direct fuel injector when removing seal ring.
    • Do not reuse seal ring.
12. Remove the high pressure fuel rail studs from the cylinder head if necessary.
 
 
INSTALLATION
 
 
1. If removed, install the high pressure fuel rail studs.
2. Install seal ring to fuel injector using the following procedure:
caution
  • Handle seal ring with bare hands. Do not wear gloves.
  • Do not apply engine oil to seal ring.
  • Do not clean seal ring with solvent.
  1. Install seal guide [SST:KV10119720 (J-50364)] (A) to fuel injector .
  2. Set seal ring into seal installer [SST:KV10119730 (J-50364)] (A).
  3. Straightly insert seal ring , which is set in step b, to fuel injector as shown and install onto fuel injector.
    cautionBe careful that seal ring does not exceed the groove portion of fuel injector.
  4. Insert drift [SST:KV10119710 (J-50364)] (A) to fuel injector and rotate clockwise and counterclockwise by 90° while pressing seal ring to fit it.
    noteThis is done to correct any elongation of the seal ring caused by installation and for preventing sticking when inserting fuel injector into cylinder head.
3. Install O-ring and backup ring to fuel injector.
caution
  • Do not reuse O-ring.
  • Handle O-ring with bare hands. Do not wear gloves.
  • Lubricate O-ring with new engine oil.
  • Do not allow engine oil into fuel passage of fuel injector.
  • Do not clean O-ring with solvent.
  • Check that O-ring and its mating part are free of foreign material.
  • When installing O-ring , be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into high pressure fuel rail.
  • Insert new O-ring straight into fuel rail. Do not decenter or twist it.
  • Always install the backup ring in the right direction as instructed.
4. Install the fuel injectors and high pressure fuel rail using the following procedure:
  1. Install the injector holder onto the fuel injector .
    caution
    • Do not reuse injector holder.
    • Be careful to keep injector holder from interfering with O-ring. If interference occurs, replace O-ring.
  2. Insert fuel injector into high pressure fuel rail with injector holder attached.
    • Insert it while matching it to the axial center.
    • Insert so that tab of injector holder is aligned to cutout of high pressure fuel rail.
  3. Check that installation is complete by checking that fuel injector does not rotate or come off.
    • Check that tabs of injector holders and high pressure fuel rail are aligned after installation.
5. Install the fuel injector and high pressure fuel rail assembly into the cylinder head and tighten the nuts and bolts using the following procedure:
  1. Temporarily tighten mounting fuel rail bolt 2 and fuel rail nut 3.
  2. Tighten mounting fuel rail nuts and bolts to the specified torque in the sequence shown.
    High pressure fuel rail nuts and bolts : 10.0 N·m (1.0 kg-m, 89 in-lb)
  3. Tighten nuts and bolts to the specified torque in the sequence shown.
    High pressure fuel rail nuts and bolts : 20.5 N·m (2.1 kg-m, 15 ft-lb)
6. Install the fuel rail pressure sensor if necessary using the following procedure:
caution
  • Do not reuse fuel rail pressure sensor.
  • Do not use fuel rail pressure sensor that has been dropped.
  • Check that high pressure fuel rail and fuel rail pressure sensor screw have no damage, foreign matter, or stains.
  • Do not use a tool on the fuel rail while tightening the fuel pressure sensor or fuel rail damage could result.
  • Do not scratch or crack high pressure fuel rail when installing fuel rail pressure sensor.
  • Apply engine oil to the threaded portion and front edge of the fuel rail pressure sensor.
  • Before tightening fuel rail pressure sensor, securely install a hexagon tool.
  1. Lubricate fuel rail pressure sensor threads with clean engine oil.
    cautionCheck that high pressure fuel rail and fuel rail pressure sensor threads have no damage or foreign matter.
  2. Tighten fuel rail pressure sensor to the specified torque.
    Fuel rail pressure sensor : 10.0 N·m (1.0 kg-m, 89 in-lb)
  3. Tighten fuel rail pressure sensor to the specified angle using angle wrench [SST:KV10112100 (BT-8653-A)].
    caution
    • To check tightening angle, use Tool. Do not judge the angle by visual inspection.
    • The torque value for the angle tightening must be 90 N·m (9.2 kg-m, 66 ft-lb) or less.
    • If torque value reaches 90 N·m (9.2 kg-m, 66 ft-lb), then replace the fuel rail pressure sensor and high pressure fuel rail with a new one.
    Tightening angle: 45°
7. Connect the fuel rail pressure sensor harness connector.
8. Connect the fuel injector harness connector.
9. Install the high pressure fuel tube. Refer to Removal and Installation.Removal and Installation
10. Install the high pressure fuel rail protector using the following procedure:
  1. Hand tighten the bolts in order number of to shown in the figure.
  2. Tighten the bolts in order number of to shown in the figure (specified torque).
    High pressure fuel rail protector bolts : 25.0 N·m (2.6 kg-m, 18 ft-lb)
11. Installation of the remaining components is in the reverse order of removal.