FUEL INJECTOR AND FUEL TUBE

Removal and Installation

• Apply new engine oil when installing the parts as specified to do so.
• Do not remove or disassemble parts unless instructed as shown.

REMOVAL

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.
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.

1. Remove engine cover.
2. Release the fuel pressure. Refer to See: Fuel Pressure\Testing and Inspection.
3. Remove front wiper arm and extension cowl top. Refer to See: Body and Frame\Cowl\Cowl Moulding / Trim\Service and Repair\Coupe (Coupe models) or See: Body and Frame\Cowl\Cowl Moulding / Trim\Service and Repair\Sedan (Sedan models).

4. Remove the electric throttle control actuator bolts in the reverse order as shown and remove the electric throttle control actuator.

CAUTION:

• Handle carefully to avoid any shock to the electric throttle control actuator.
• Do not disassemble.

5. Remove intake manifold collector. Refer to See: Engine, Cooling and Exhaust\Engine\Intake Manifold\Service and Repair\Intake Manifold Collector.
6. When separating fuel feed hose and fuel tube connection, disconnect quick connector as follows:

1. Remove quick connector cap from quick connector.
2. Disconnect quick connector from fuel tube as follows:

CAUTION:
Disconnect quick connector by using the quick connector release (commercial service tool: J-45488), not by picking out retainer tabs.

9. With the sleeve side of quick connector release facing to quick connector, install the quick connector release onto fuel tube.

2. Insert the quick connector release (A) into quick connector (2) until sleeve (B) contacts and goes no further. Hold quick connector release on that position.

C : Insert and retain

CAUTION:
Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.

3. Draw and pull out quick connector straight from fuel tube (1).

CAUTION:

• Pull quick connector (E) holding position (D) as shown in the figure.
• Never pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leakage out.
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around them.
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal.

• To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or something similar.

7. Disconnect harness connector from fuel injector.

8. Loosen bolts in reverse order as shown, and remove fuel tube and fuel injector assembly.

White arrow indicates Engine front

CAUTION:
Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.

9. Remove fuel injector from fuel tube as follows:

1. Open and remove clip (1).

3 : O-ring (green)
4 : O-ring (black)
A : Installed condition
B : Clip groove

2. Remove fuel injector (2) from fuel tube (5) by pulling straight.

CAUTION:

• Be careful with remaining fuel that may go out from fuel tube.
• Be careful not to damage injector nozzle during removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector.

10. Remove fuel damper from fuel tube.

INSTALLATION

1. Install fuel damper as follows:

1. Install new O-ring (2) to fuel tube (1) as shown. When handling new O-ring, be careful of the following caution:

CAUTION:

• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never 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, never insert it quickly into fuel tube.

• Insert new O-ring straight into fuel tube. Never twist it.

2. Install spacer (3) to fuel damper (4).
3. Insert fuel damper straight into fuel tube.

CAUTION:

• Insert straight, checking that the axis is lined up.
• Never pressure-fit with excessive force.

Reference value : 130 N (13.3 kg, 29.2 lb)

• Insert fuel damper until (B) is touching (A) of fuel tube.

4. Tighten bolts evenly in turn.

• After tightening bolts, check that there is no gap between fuel damper cap (5) and fuel tube.

2. Install new O-rings to fuel injector paying attention to the following.

CAUTION:

• Upper and lower O-ring are different. Be careful not to confuse them.

• Lubricate O-ring with new engine oil.
• Never 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, never insert it quickly into fuel tube.
• Insert O-ring straight into fuel injector. Never decenter or twist it.

3. Install fuel injector to fuel tube as follows:

1. Insert clip (3) into clip groove (F) on fuel injector (5).

2 : O-ring (black)
4 : O-ring (green)

• Insert clip so that protrusion (E) of fuel injector matches cutout (C) of clip.

CAUTION:

• Never reuse clip. Replace it with new one.
• Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.

2. Insert fuel injector into fuel tube (1) with clip attached.

• Insert it while matching it to the axial center.

• Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip.
• Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip.

3. Check that installation is complete by checking that fuel injector does not rotate or come off.

• Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.

4. Install fuel tube and fuel injector assembly to intake manifold.

CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.

• Tighten bolts in two steps in numerical order as shown in the figure.

White arrow indicates Engine front

5. Connect fuel injector harness.
6. Install intake manifold collector. Refer to See: Engine, Cooling and Exhaust\Engine\Intake Manifold\Service and Repair\Intake Manifold Collector.
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:

1. Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them.
2. Thinly apply new engine oil around fuel tube from tip end to spool end.
3. Align center to insert quick connector straightly into fuel tube.

• Insert quick connector (1) to fuel tube until top spool (2) is completely inside quick connector, and 2nd level spool (3) exposes right below quick connector.

B : Fitted condition
White arrow indicates Upright insertion

CAUTION:

• Hold (A) position as shown in the figure when inserting fuel tube into quick connector.
• Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
• Insert until you hear a "click" sound and actually feel the engagement.
• To avoid mis-identification of engagement with a similar sound, be sure to perform the next step.

4. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does not come out from fuel tube.

5. Install quick connector cap (3) to quick connector.

1 : Fuel feed hose
2 : Fuel tube
B : Upper view

• Install quick connector cap with arrow (A) on surface facing in direction of quick connector (fuel feed hose side).

CAUTION:
If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again.

6. Secure fuel feed hose to clamp of quick connector cap.

8. Installation is in the reverse order of removal.

Inspection AFTER INSTALLATION
Make sure there is no fuel leakage at connections as follows:

1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.

CAUTION:
Do not touch engine immediately after stopping as engine is extremely hot.

NOTE:
Use mirrors for checking on connections out of the direct line of sight.

• Perform procedures for "Throttle Valve Closed Position Learning" after finishing repairs. Refer to See: Computers and Control Systems\Testing and Inspection\Programming and Relearning\Throttle Valve Closed Position Learning\Description.
• If electric throttle control actuator is replaced, perform procedures for "Idle Air Volume Learning" after finishing repairs. Refer to See: Idle Speed\Testing and Inspection\Idle Air Volume Learning\Description.