Fuel Injector and Fuel Tube: Removal and Installation [VQ40DE]: Installation

Install fuel damper as follows:

Fig 1: Identifying Fuel Damper
Courtesy of SUZUKI OF AMERICA CORP.
1. Install new O-ring to fuel tube as shown.
  - When handling new O-rings, be careful of the following caution:
  CAUTION:
  - Handle O-ring with bare hands. Never wear gloves.
  - Lubricate new 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, do not 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.
2. Install spacer to fuel damper.
3. Insert fuel damper straight into fuel tube.
  CAUTION:
  - Insert straight, making sure that the axis is lined up.
  - Do not 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, make sure that there is no gap between fuel damper cap and fuel tube.
Install new O-rings to fuel injector, paying attention to the following.
CAUTION:
- Upper and lower O-ring are different colors.
  Fuel tube side: Blue
  
  Nozzle side: Brown
- Handle O-ring with bare hands. Never 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 O-ring straight into fuel injector. Do not angle or twist it.
Install fuel injector to fuel tube.

Fig 2: Identifying Fuel Injector And Fuel Tube
Courtesy of SUZUKI OF AMERICA CORP.
1. Insert new clip into clip mounting groove on fuel injector.
  - Insert 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.
Connect the fuel tube (RH) to the fuel tube (LH), and tighten bolts temporarily.
- Tighten bolts to the specified torque after installing fuel tube and fuel injector assembly.
CAUTION:
- 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 tube and fuel injector assembly to intake manifold.
CAUTION: Do not let the tip of the injector nozzle come in contact with other parts.
- Tighten bolts in two steps in numerical order as shown.
  
  Fig 3: Identifying Fuel Injector Assembly Bolts Tightening Sequence
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Fuel injector tube assembly bolts
  
  1st step: 10.1 N.m (1.0 kg-m, 7 ft-lb)
  
  2nd step: 22.0 N.m (2.2 kg-m, 16 ft-lb)
Tighten bolts which connect fuel tube (RH) and fuel tube (LH) to the specified torque.
Connect fuel injector harness connector.
Install intake manifold collector. Refer to [INTAKE MANIFOLD COLLECTOR: REMOVAL AND INSTALLATION ].
Installation of the remaining components is in the reverse order of removal.