1. Fuel hose; 2. Cap of the quick-release fitting; 3.Fuel pipe; 4. Protective cover for the fuel pipe; 5. O-ring (blue); 6. Clamp; 7. Fuel injector; 8. O-ring (brown); 9. Intake manifold support.
Attention. Do not remove or disassemble components unless instructed to do so in the illustration.
Removal and installation
Removal
Attention:
- When carrying out work in a service station, hang a sign «FLAMMABLE».
- Carry out work in a well-ventilated place. Keep a CO2 fire extinguisher on hand.
- Do not smoke when servicing the fuel system. Do not light fire or produce sparks.
1. Relieve fuel pressure. See chapter "Engine management system".
2. Remove the air cleaner housing, mass air flow sensor and air duct assembly. See above.
3. Disconnect the quick release fitting (A) as follows:
1. Fuel hose.
Attention. Disconnect the quick-release fitting using a puller (special tool), rather than by pulling out the locking tabs.
A. Remove the cap from the quick release fitting.
b. Put on the puller (special tool) onto the fuel pipe with the sleeve towards the quick-release fitting.
With. 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.
d. 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. Remove the intake manifold. See above.
5. Disconnect the intermediate wiring from the fuel injectors.
6. 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.
7. Remove the fuel injectors from the fuel pipe as follows:
- A. Release the clamp (1) and remove it.
- b. Remove the fuel injector (2) from the fuel pipe (3) at right angles.
Attention:
- Do not spill any remaining fuel from the fuel pipe.
- Be careful not to damage the fuel injector nozzle when removing.
- Do not drop or hit fuel injectors.
- Do not disassemble fuel injectors.
Installation
1. When installing new O-rings into the fuel injector, observe the following:
Attention:
- The upper and lower O-ring are different. Don't confuse them.
- Fuel pipe side blue
- The nozzle side is brown
- 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 insert it into the fuel pipe immediately.
- Insert the O-ring into the fuel pipe at a right angle. Do not move or twist it.
2. Insert the fuel injectors into the fuel pipe as follows:
3. O-ring (blue).
4. O-ring (brown).
A. Insert the clamp (3) into the groove (F) on the fuel injector (5).
Insert the clamp so that the protrusion (E) on the fuel injector aligned with the cutout (WITH) on the clamp.
Attention:
- Do not reuse clips. Replace them with new ones.
- Place the clamp so that it does not touch 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 (A) fuel pipe (1) entered the cutout (IN) on the clamp.
- Make sure the flange (G) fuel pipe is securely fixed in the installation groove (D) on the clamp.
With. Check for proper installation by making sure the fuel injector does not rotate or jump off.
3. Install the fuel pipe and fuel injector assemblies as follows:
A. Insert the fuel injector tips into the intake manifold support.
b. Tighten the mounting bolts in the order indicated by the numbers in the figure.
4. Connect the intermediate wiring to the fuel injectors.
5. Install the intake manifold. See above.
6. When connecting quick-release fittings and fuel hose, observe the following:
A. Make sure there is no damage or foreign matter deposited in or around the fuel pipe and quick connect fitting.
b. Align the centers and insert the quick release fitting into the fuel pipe at a right angle.
Note. The illustration shows the connection on the motor side as an example.
- 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:
With. Before securing the fuel pipe with a clamp, pull the quick-release fitting, holding the section «A». Make sure it is fully engaged (connected) so that it does not come off the fuel pipe
d. Install the cap onto the quick release fitting.
- Place the cap on the quick-release fitting with the arrow pointing upward.
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 on the quick-release fitting, the quick-release fitting may not be installed correctly, check the connection again.
7. Secure the fuel hose with a clamp.
8. After this operation, installation is performed in the reverse order of removal.
Check after installation
Checking for fuel leaks
1. Turn the ignition key to ON position (without starting the engine). After creating pressure in the fuel lines, check for fuel leaks at the joints.
Note. Use mirrors to check in hard-to-reach places.
2. Start the engine. After increasing the engine speed, check again for fuel leaks at the junction of the fuel lines.
Attention. Do not touch the engine immediately after stopping as it becomes very hot.