Fuel injectors and fuel pipes 1. Fuel hose; 2. Bracket; 3. Cap of quick-release fitting; 4. Fuel pipe; 5. O-ring (black); 6. Clamp; 7. Fuel injector; 8. O-ring (green); A. To the central fuel line under the bottom.
Attention. Do not remove or disassemble components unless instructed to do so in the illustration.
Removal and installation
Attention:
- When carrying out work in a service station, hang a sign «FLAMMABLE».
- Carry out work in a well-ventilated area. A fire extinguisher should be on hand.
- Do not smoke when servicing the fuel system. Do not light fire or produce sparks.
Removal
1. Relieve fuel pressure. See chapter "Engine management system".
2. Remove the intake manifold. See above.
3. Disconnect the quick release fitting as follows.
- Disconnect the fuel hose (1) from the fuel pipe (3)
Note. This model does not have a fuel exhaust system.
A. Remove the cap (2) from a quick-release fitting.
b. Remove the fuel hose from the clamp.
With. Put on the puller (special tool) onto the fuel pipe with the sleeve towards the quick-release fitting.
d. Insert the puller into the quick-release fitting until the sleeve rests against it. Lock the puller in this position.
Attention. The quick release fitting will not come off if you push the puller in with too much force. Fix the puller in such a position that it rests against the fitting.
e. Pull straight and remove the quick release fitting from the fuel pipe.
Attention:
- Pull the quick release fitting while holding the section «A», as shown in the picture.
- Don't pull sideways. Otherwise, the O-ring inside the quick release fitting may be damaged.
- Since fuel will spill, stock up on a container and a rag in advance.
- Do not light fire or produce sparks.
- Keep components away from heat sources. Be especially careful when performing welding work.
- Do not expose components to battery fluid or other acids.
- When removing/installing, do not bend or twist the area between the quick release fitting and the fuel hose.
- To keep the connection area clean and to prevent damage and foreign particles, plug the openings of the disconnected pipes with plugs or cover them with plastic bags.
4. Disconnect the connectors from the fuel injectors.
5. Remove the fuel injectors and fuel pipe assembly.
- Loosen the mounting bolts in the reverse order shown in the illustration.
Attention. Make sure the fuel injector nozzle does not come into contact with other components.
- Collect any remaining fuel that has spilled from the tube with a napkin.
6. Remove the fuel injector (3) from the fuel pipe (1), as follows:
A. Release the clamp (2) and remove it. Remove the fuel injectors from the fuel pipe at a right angle.
Attention:
- Do not spill any remaining fuel from the fuel pipe.
- Be careful not to damage the injector nozzle when removing it.
- Do not drop or hit fuel injectors.
- Do not disassemble fuel injectors.
Installation
1. Observe the following when installing new O-rings into the fuel injector.
Attention.
- The upper and lower O-ring are different. Don't confuse them.
- Fuel pipe side: black.
- From the nozzle side: green.
- Handle the O-rings with bare hands. Don't wear gloves.
- Lubricate the O-rings with engine oil.
- Do not clean O-rings with solvent.
- Make sure there are no foreign particles on the O-ring or seal surface.
- When installing, do not scratch the seals with tools or your fingernails. Also, do not twist or stretch the O-rings. If the O-ring is stretched during installation, do not immediately insert it into the fuel pipe
- Insert the O-ring into the fuel pipe at a right angle. Do not move or twist it.
2. Insert the fuel injector (4) into the fuel pipe (1) as follows:
A. Insert the clamp (2) into the groove (F) on the fuel injector.
- Insert the clamp so that the protrusion (G) on the fuel injector aligned with the cutout (D) on the clamp.
Attention. Do not reuse clips. Replace them with new ones.
- Position the clamp so that it does not interfere with the O-ring. Otherwise, replace the O-ring.
b. Insert the fuel injector into the fuel pipe with the clamp attached.
- Insert it while maintaining centering.
- Insert the fuel injector so that the protrusion (IN) fuel pipe entered the cutout (WITH) on the clamp.
- Make sure the flange (A) fuel pipe is securely fixed in the installation groove (E) on the clamp.
3. O-ring (black).
5. O-ring (green).
With. Check for proper installation by making sure the fuel injector does not rotate or come off.
3. Place the fuel pipe and fuel injector assembly on the cylinder head.
Attention. Do not allow the fuel injector nozzle tip to come into contact with other components.
4. Install the fuel pipe and fuel injector assemblies to the cylinder head.
- Tighten the mounting bolts in the order indicated by the numbers in the figure.
5. Connect the electrical wiring to the fuel injectors.
6. Connect the fuel hose as follows.
A. Make sure there is no damage or foreign matter deposited in or around the fuel pipe and quick connect fitting.
b. Apply a thin layer of fresh engine oil to the tip of the fuel pipe.
With. Align the centers and insert the quick-release fitting into the fuel pipe without distortion.
- Insert the quick connect fitting into the fuel pipe until the first collar on the fuel pipe is completely seated in the quick connect fitting and the second collar is under the bottom edge of the quick connect fitting.
Attention:
- When inserting the fuel pipe into the quick-release fitting, hold it by the area «A», as shown in the picture.
- To avoid damaging the O-ring inside the quick-release fitting due to misaligned installation, ensure that the centers are precisely aligned.
- Insert until you hear a click and feel actual engagement.
- To avoid confusing the engagement with a similar sound, perform the following operation:
d. Before securing the fuel pipe with a clamp, pull the quick-release fitting while holding the section «A». Make sure it is fully seated and engaged (connected) so that it does not jump off the fuel pipe.
e. Install the cap (2) to the quick release fitting.
1. Fuel hose.
3. Fuel pipe.
- Install the cap on the quick-release fitting with the arrow pointing toward the quick-release fitting (towards the fuel hose).
Attention:
- Make sure the quick connect fitting and fuel tube are securely engaged in the mounting groove on the quick connect fitting cap.
- If the cap is difficult to install onto the quick-release fitting, the quick-release fitting may not be installed correctly. Remove the quick connector cap and check the connection again.
1. Secure the fuel hose with a clamp.
7. Install the remaining components in the reverse order of removal.
Check after installation
Checking for fuel leaks
1. Create pressure in the fuel lines by turning the ignition key to the ON position (without starting the engine). Then check for fuel leaks at the joints.
Note. Use mirrors to check in hard-to-reach places.
2. Start the engine. While increasing the engine speed, check again for fuel leaks at the joints of the fuel lines.
Attention. Do not touch the engine immediately after stopping as it becomes very hot.