Fuel Injector ASSY: Replacement

1. Remove the 2 bolts then remove the engine room relay block No. 2.
2. Remove the 4 wire harness clamps. See Fig 2.
   Fig 2: Identifying 4 Wire Harness Clamps

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3. Remove the 7 bolts, then remove the cowl top panel outer front. See Fig 3.
   Fig 3: Identifying 7 Bolts

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1. Disconnect the brake fluid level switch connector.
2. Remove the 2 bolts.
3. Separate the claw fitting, then remove the brake master cylinder reservoir. See Fig 5.
   Fig 5: Locating Claw Fitting

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1. Remove the fuel vapor feed hose No. 2 from the hose clamp.
2. Remove the connector clamp.
3. Remove the wire harness clamp.
4. Remove the 3 bolts, then remove the reservoir bracket. See Fig 6.
   Fig 6: Removing Reservoir Bracket

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1. Remove the 2 wire harness clamps.
2. Disconnect the 4 fuel injector connectors.
3. Disconnect the 4 ignition coil connectors.
4. Remove the 3 bolts, then remove the engine wire and brake master cylinder reservoir cover. See Fig 7.
   Fig 7: Identifying Wire Harness Clamps, Fuel Injector Connectors And Ignition Coil Connectors

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5. Remove the 4 bolts, then remove the 4 ignition coils. See Fig 8.

   HINT: 

   Each ignition coil is installed with 1 bolt.

   Fig 8: Identifying Ignition Coil Bolts

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6. Disconnect the ventilation hose from the ventilation valve. See Fig 9.
7. Disconnect the ventilation hose No. 2 from the cylinder head cover.
   Fig 9: Disconnecting Ventilation Hoses

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8. Remove the 9 bolts, 2 seal washers and 2 nuts, then remove the cylinder head cover. See Fig 10.
   Fig 10: Locating Cylinder Head Cover Bolts

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1. Disconnect the fuel tube from the fuel delivery pipe.
   1. Remove the EFI fuel pipe clamp No. 1.
   2. Pinch the retainer of the fuel tube connector, then pull put the fuel tube connector to disconnect the fuel tube from the fuel delivery pipe. See Fig 11
      Fig 11: Disconnecting The Fuel Tube From The Fuel Delivery Pipe

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   NOTE:

   • Remove dirt or foreign objects on the fuel tube connector before this work.
   • Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.
   • Perform this work by hand. Do not use any tools.
   • Do not forcibly bend, twist or turn the nylon tube.
   • Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tube.
   • If the fuel tube connector and pipe are stuck, push and pull them to release.
   Fig 12: Fuel Tube Connector

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2. Remove the 3 bolts, then remove the fuel delivery pipe together with the 4 fuel injectors. See Fig 13.
   NOTE: Do not drop the fuel injectors when removing the fuel delivery pipe.
   Fig 13: Removing 3 Bolts And The Fuel Delivery Pipe

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3. Remove the 2 delivery pipe No. 1 spacers from the cylinder head. See Fig 14.
4. Remove the 4 insulators from the cylinder head.
   Fig 14: Locating Delivery Pipe No. 1 Spacers & 4 Insulators

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1. Pull out the 4 fuel injectors from the fuel delivery pipe. See Fig 15.
   Fig 15: Pull Out Fuel Injectors

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1. Apply a light coat of spindle oil or gasoline to a new O-ring, then install it to each fuel injector. See Fig 16
   Fig 16: Install NEW O-Ring

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2. Apply a light coat of spindle oil or gasoline to the surface of the fuel delivery pipe which contacts the O-ring of the fuel injector.
3. Apply a light coat of spindle oil or gasoline to the O-ring again, then turning the fuel injector right and left to the fuel delivery pipe.
   NOTE: Be careful that the O-ring is not cracked or jammed when installing.
4. Check that the fuel injector rotates smoothly. See Fig 17. If the fuel injector does not rotate, replace the O-ring.
   Fig 17: Checking Fuel Injector Rotation

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1. Install 4 new insulators to the cylinder head. See Fig 18.
2. Install the 2 delivery pipe No. 1 spacers to the cylinder head.
   NOTE: Be careful of the installation direction of the delivery pipe spacer.
   Fig 18: Installing 4 NEW Insulators & 2 Delivery Pipe No. 1 Spacers To The Cylinder Head

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3. Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 3 bolts. See Fig 19.
   NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe.
4. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring.
5. Retighten the 3 bolts with the specified torque. See Fig 19.

   Torque: 

   19 N.m (194 kgf.cm, 14 ft.lbf) for bolt A 

   9.0 N.m (92 kgf.cm, 80 in.lbf) for bolt B 

   Fig 19: Locating 3 Bolts

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6. Connect the fuel tube to the fuel delivery pipe.
   1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube to the fuel delivery pipe.
      NOTE:

      • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this work.
      • After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling them.
   2. Install the EFI fuel pipe clamp No. 1. See Fig 20.
      Fig 20: Installing The EFI Fuel Pipe Clamp No. 1

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1. Apply seal packing to the cylinder head as illustrated. See Fig 21

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not start the engine within 2 hours of installation.
   Fig 21: Locating Seal Packing

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2. Tighten the 9 bolts, 2 seal washers and 2 nuts in the sequence shown in the illustration to install the cylinder head cover. See Fig 22.

   Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

3. Connect the ventilation hose No. 2 to the cylinder head cover.
4. Connect the ventilation hose to the ventilation valve.
5. Install the 4 ignition coils with the 4 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

6. Install the engine wire and brake master cylinder reservoir cover with the 3 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

7. Connect the 4 ingition coil connectors.
8. Connect the 4 fuel injector connectors.
9. Install the 2 wire harness clamps.
   Fig 22: Cylinder Head Cover Bolt Tightening Sequence

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1. Temporarily install the reservoir bracket with the bolt 1.
2. Tighten the 3 bolts with the specified torque in the sequence shown in the illustration. See Fig 23.

   Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

3. Install the connector clamp.
4. Install the wire harness clamp.
5. Install the fuel vapor feed hose No. 2 to the hose clamp.
   Fig 23: Reservoir Bracket Bolt Tightening Sequence

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Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

Torque: 6.4 N.m (65 kgf.cm, 57 in.lbf)