Injector ASSY (FA20/direct fuel injection): Installation

1. Use the engine conditioner to remove the carbon on engine oil on the side surface and seal groove of injector shown in the figure.
   Fig 1: Checking Fuel Injector Seal Cleaning Area

   Courtesy of SUBARU OF AMERICA, INC.
   CAUTION:

   • Do not clean the tip portion.
   • Do not use a wire brush etc.
   • If the tip of fuel injector ASSY is bumped or dropped, replace the fuel injector ASSY with a new one.
2. Apply engine oil to the inner periphery of SST (guide) and set it on the injector so that the taper surface faces toward the tip side of injector.

   SST 09260-39020

   Fig 2: Applying Engine Oil To Inner Periphery Of SST (Guide)

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3. Install a new fuel injector seal to the SST (holder).

   SST 09260-39020

   Fig 3: Installing Fuel Injector Seal To SST (Holder)

   Courtesy of SUBARU OF AMERICA, INC.
   CAUTION: When setting the fuel injector seal on the SST (holder), the seal is stretched and it is difficult to correct if the seal is set at an angle.
4. Set the SST (holder) with the fuel injector seal to the tip of injector and push down the fuel injector seal with fingers to install it in the injector groove shown in the figure.

   SST 09260-39020

   Fig 4: Installing Fuel Injector Seal

   Courtesy of SUBARU OF AMERICA, INC.
   CAUTION: Make sure the fuel injector seal is completely fitted in the groove for its entire circumference.
5. While holding the fuel injector seal (connector side) lightly with the SST (holder), pull up the SST (guide) toward the injector tip side slowly and seat the fuel injector seal in the injector groove.

   SST 09260-39020

   Fig 5: Checking Fuel Injector Seal Proper And Improper Installation Position

   Courtesy of SUBARU OF AMERICA, INC.
   CAUTION: Be careful not to pinch the fuel injector seal between the SST (guide) and injector groove. If it is pinched, replace it with a new one.
6. Pull up the SST (guide) toward the injector tip side slowly and hold the SST for 5 sec. or more when the fuel injector seal on the connector side reaches to the straight portion of SST (guide) in order to correct the fuel injector seal.

   SST 09260-39020

   Fig 6: Pulling Up SST (Guide) From Injector Tip Side

   Courtesy of SUBARU OF AMERICA, INC.
   CAUTION: Be careful not to pinch the fuel injector seal between the SST (guide) and injector groove. If it is pinched, replace it with a new one.
   NOTE:

   • A rough indication of the straight portion is the position where the bottom of fuel injector seal aligns with the bottom of SST (guide).
   • When the SST (guide) cannot be pulled up because it is stuck, pull up it gradually by rotating the SST (guide) to the left and right slowly.
7. After the fuel injector seal is installed, make sure that there is no scratches on the seal, crushing of the seal, or protrusion of the seal from the seal groove.

Fig 7: Identifying Fuel Injector Seal Proper And Improper Installation Position

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1. Install a new back-up ring NO. 2, new fuel injector seal and new back-up ring NO. 1 as shown in the figure.
   Fig 8: Identifying Back-Up Ring No. 2, Fuel Injector Seal And Back-Up Ring No. 1 Proper And Improper Installation Position

   Courtesy of SUBARU OF AMERICA, INC.
   CAUTION:

   • There must be no foreign matter, scratches, etc. in the fuel injector seal groove of injector.
   • Be careful not to mix up the directions of back-up springs NO. 1 and NO. 2.
   • Be careful not to mix up the installation order of back-up spring and fuel injector seal.
   • There must be no running on or widening of back-up ring gap portion as shown in the figure.
   • After the installation, there must be no foreign matter, scratches, etc. in the fuel injector seal.
2. Install a new fuel injector insulator and new O-ring.
   Fig 9: Identifying C-Ring And Fuel Injector Insulator

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   CAUTION: Install the fuel injector insulator in the direction as shown in the figure.
   Fig 10: Installing Fuel Injector Insulator

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3. Install the fuel injector holder to the fuel injector ASSY.
   Fig 11: Identifying Fuel Injector Holder

   Courtesy of SUBARU OF AMERICA, INC.
4. Apply new engine oil to the chamfered portions of injector insertion holes of the fuel delivery pipes (bank 2 side) and (bank 1 side).
5. Align the protrusion of fuel injector holder to the arrest holes of fuel delivery pipes (bank 2 side) and (bank 1 side) to install the fuel injector holder.

Fig 12: Aligning Protrusion Of Fuel Injector Holder To Arrest Holes Of Fuel Delivery Pipes (Bank 2 Side) And (Bank 1 Side)

Courtesy of SUBARU OF AMERICA, INC.

Fig 13: Identifying Flow Stratified Number And QR Code

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1. Install the fuel delivery pipe (bank 2 side) with the two bolts.

   Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf}

2. Connect the two fuel injector connectors.

1. Install the fuel delivery pipe (bank 1 side) with the two bolts.

   Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf}

2. Connect the two fuel injector connectors and fuel pressure sensor connector.

1. Temporarily tighten the nut for new fuel delivery pipe until it is seated.
2. Temporarily install the fuel delivery pipe with the three bolts.
3. Tighten the three bolts.

   Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}

4. Tighten the fuel delivery pipe.

   Standard value: T=25N.m {255kgf.cm} {18.4ft.lbf}

1. Temporarily tighten the nut for new fuel delivery pipe No. 2 until it is seated.
2. Tighten the fuel delivery pipe NO. 2.

   Standard value: T=25N.m {255kgf.cm} {18.4ft.lbf}

(Refer to INSTALLATION )