Fuel Injector: Service and Repair

REMOVAL
1. Relieve fuel pressure according to procedure described on "FUEL PRESSURE RELIEF PROCEDURE".
2. Disconnect negative cable (-) at battery.
3. Detach intake manifold stiffener (front) (1) from intake manifold (for G16 engine).
4. Remove PCV hose and breather hose (for J20 engine).




5. Disconnect coupler (1) from each injector.




6. Remove clamp bolt (1) for fuel feed pipe and return pipe.
7. Remove fuel delivery pipe bolts.




8. Remove fuel injector(s) (1) from delivery pipe (2) and intake manifold or cylinder head.

WARNING: A small amount of fuel may be released when fuel injector is removed. In order to reduce the chance of personal injury, cover them with a shop cloth.




INSTALLATION
1. Replace injector O-ring(3) with new one using care not to damage it. Install grommet (2) to injector.
2. Check if insulator (1) is scored or damaged. If it is, replace with new one.
Install insulators and cushions (4) to intake manifold or cylinder head.




3. Apply thin coat of fuel to O-rings(1) and then install injectors into delivery pipe and intake manifold or cylinder head. Make sure that injectors rotate smoothly. If not, probable cause is incorrect installation of O-ring. Replace O-ring with new one.
4. Tighten delivery pipe bolts and make sure that injectors rotate smoothly.

Tightening torque
Fuel delivery pipe bolt (a):
23 N.m (2.3 kg.m, 17.0 lb-ft)

6. Install intake manifold stiffener (front) to intake manifold (for G16 engine).
Install PCV hose and breather hose and clamp then securely (for J20 engine).
7. Install clamp bolts for fuel feed pipe and return pipe.
8. Connect negative cable to battery.
9. With engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.