Fuel Injector and Fuel Tube: Removal and Installation [QR25DE]: Installation

Install new O-rings to fuel injector, paying attention to the following.
CAUTION:
- Upper and lower O-rings are different colors.
  Fuel tube side: Black
  
  Nozzle side: Green
- Handle O-ring with bare hands. Do not wear gloves.
- Lubricate O-ring with new engine oil.
- Do not clean O-ring with solvent.
- Make sure 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.
- Do not twist or stretch O-ring. If O-ring was stretched while it was being attached, allow it to retract before inserting it into fuel tube.
- Insert new O-ring straight into fuel tube. Do not angle or twist it.
Install fuel injector to fuel tube.

Fig 1: Identifying Fuel Injector And Fuel Tube
Courtesy of SUZUKI OF AMERICA CORP.
1. Insert clip into clip mounting groove on fuel injector.
  - Insert new clip so that protrusion of fuel injector matches cutout of clip.
  CAUTION:
  - Do not reuse clip. Replace it with a new one.
  - Do not allow the clip to interfere with the O-ring. If interference occurs, replace O-ring.
2. Insert the fuel injector into the fuel tube with the clip attached.
  - Insert it while matching it to the axial center.
  - Insert fuel injector so that protrusion of fuel tube matches cutout of clip.
  - Make sure that fuel tube flange is securely fixed in flange fixing groove on clip.
3. Make sure that installation is complete by checking that the fuel injector does not rotate or come off.
  - Make sure that protrusions of the fuel injectors are aligned with cutouts of clips after installation.
Install fuel tube and fuel injector assembly as follows:
CAUTION: Do not let the tip of the injector nozzle come in contact with other parts.
1. Insert the tip of each fuel injector into intake manifold.
2. Tighten bolts in two steps in numerical order as shown.
  
  Fig 2: Identifying Fuel Injector Assembly Bolts Tightening Sequence
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Fuel tube bolts
  
  1st step: 12.8 N.m (1.3 kg-m, 9 ft-lb)
  
  2nd step: 28.0 N.m (2.9 kg-m, 21 ft-lb)
Connect harness connectors to fuel injectors.
Install intake manifold. Refer to [INTAKE MANIFOLD: REMOVAL AND INSTALLATION ]
Connect quick connector at the engine side as follows:
1. Check the connection for foreign material and damage.
2. Align center to insert quick connector straight into fuel tube.
  
  Fig 3: Aligning Center To Insert Quick Connector Straight Into Fuel Tube
  Courtesy of SUZUKI OF AMERICA CORP.
  
  NOTE: The figure shows the engine side as an example.
  - Insert quick connector to fuel tube until the top spool on fuel tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end.
  CAUTION:
  - Hold (A) position as shown 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.
3. Before clamping fuel feed hose with quick connector cap, pull quick connector hard by hand holding (A) position. Make sure it is completely engaged (connected) so that it does not come out from fuel feed tube.
4. Install quick connector cap to quick connector connection. (engine side)
  
  Fig 4: Installing Quick Connector Cap To Quick Connector Connection (Engine Side)
  Courtesy of SUZUKI OF AMERICA CORP.
  - Install so that the arrow mark on the side faces up.
  CAUTION:
  - Make sure that quick connector and fuel tube are securely fit into quick connector cap installation groove.
  - If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check the connection again.
Install fuel feed hose to hose clamp.
Installation is in the reverse order of removal after this step.