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 on the fuel rail as a set.

3. Fuel Pipe and Injector - Remove

2.
Disconnect the fuel pressure sensor connector (B) and the injector connectors (C).
3.
Remove the fuel rail mounting bolts (D) and nuts (E).
4.
Carefully remove the fuel rail (F) with the injectors straight from the cylinder head.
NOTE:
If the injector remained 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 the new injector clip (G).

4. 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 on the fuel rail as a set.

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.
Install the sizing tool (A) to the injector (B) as shown.
NOTE: Do not touch the tool to the top of the injector.
3.
Install the seal guide (A) over the tip of the injector (B) as shown.
4.
Slide a new seal (A) on the seal guide as shown.
5.
Slide the seal installer (A) onto the seal guide, then quickly push the seal down to the groove (B) of the injector.
6.
Remove the seal guide and the seal installer from the injector.
7.
Move the sizing tool and align the top of the injector surface (A) and the tool's inner surface (B) as shown, and hold the tool to reform the seal for 30 seconds or more.
NOTE: Make sure the seal (C) is not deformed when moving the tool.
8.
Remove the sizing tool, and check that the seal is installed correctly.
NOTE: When cleaning the sizing tool and the seal guide, be careful not to scratch the sizing tool bore or the surface of the seal guide.

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.
2.
Coat the O-ring with clean engine oil, then install the injector (C) to the fuel rail (D) with a new injector clip (E).
NOTE: When installing the injector, be sure to protect the injector from dust or debris.

3. Fuel Pipe and Injector - Install
1.
Coat the injector holes (A) on the cylinder head 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 debris.

3.
Install the nuts (C), and tighten slowly and alternately until the fuel rail sits on the cylinder head.
4.
Tighten the nuts and the bolts (D) to the specified torque.
5.
Connect the injector connectors (E) and the fuel pressure sensor connector (F).


5. Fuel Line 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.