Injector Removal and Installation
Special Tools Required
Image Description/Tool Number
9576256.png Pick Up Tool 070AC-5A0A100
9507995.png Injector Seal Installer Kit 070AG-5A0A100

NOTE: When replacing the injector, you must replace all injectors as an assembly and the fuel joint pipe. Failure to do so will cause poor engine performance and fuel leaks.

4. Fuel Rail Cover - Remove

6. Fuel Pipe and Injector - Remove
1.
Disconnect the connectors (A).
2.
Carefully remove the fuel rail (B) with the injectors (C) straight from the cylinder head.
NOTE:
If the injector remains on the cylinder head, carefully remove the injector straight from the cylinder head.
Note the cylinder number of the injector, and install it to the same cylinder when reinstalling.
If you replace the injector, the fuel rail, or the cylinder head, use a new injector clip (D).

7. Injector - Remove
1.
Remove the injectors (A) from the fuel rail.
2.
Remove the injector clip (B), the O-ring (C) and the back-up ring (D) from the injector.
NOTE: If you replace the injector, the fuel rail, or the cylinder head, use a new injector clip, O-ring, and back-up ring.
3.
Using the pick up tool (A), carefully remove the seal (B) from the injector.


NOTE: When replacing the injector, you must replace all injectors as an assembly and the fuel joint pipe. Failure to do so will cause poor engine performance and fuel leaks.

1. Injector Seal - Install
1.
With a paper towel, carefully wipe off any carbon from the area (A) shown.
NOTE:
Do not wipe off the tip area (B) of the injector as it may be damaged.
If the tip of the injector is dirty or clogged, it must be replaced. The injectors cannot be cleaned.
2.
Quickly push a new seal (A) down to the groove (B) of the injector using the seal guide tool (C) and the seal installer (D).
3.
Joint the sizing tools (A), then slide them as a set onto the seal (B) until tools touch to the injector stepped surface (C) as shown, and hold the tools to reform the seal for 30 seconds or more.
4.
Remove the sizing tool, and check that the seal is installed correctly.
NOTE: When cleaning the sizing tool, be careful not to scratch the sizing tool bore.

2. Injector - Install
1.
Install a new back-up ring (A) and a new O-ring (B) on the injector (C).

NOTE:
Set the direction of the back-up ring as shown
Check that the back-up ring sets correctly after installation.
Use compressed air to insure that there are no dust or debris around the ring.
2.
Coat the O-ring with clean engine oil, then install the injector onto the fuel rail (D) with a new clip (E).
NOTE: When installing the injector, be sure to protect the injector from dust or debris.

3. Fuel Pipe and Fuel Injector - Install
1.
Coat the injector holes on the cylinder head (A) with clean engine oil.
2.
Carefully install the fuel rail (B) with the injectors into the cylinder head straight and equal.
NOTE: When installing the injector, protect the tip of the injector from dust or debris.
3.
Install the nuts (C), and tighten them slowly in an alternate pattern until the fuel rail sits on the cylinder head.
4.
Tighten the nuts and the bolts (D) to the specified torque.
5.
Connect the connectors (E).

5. Fuel Leak (Low Pressure Side) - Check
1.
Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then check for fuel leakage.

7. Fuel Rail Cover - Install