INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL FUEL INJECTOR SEAL

(a) Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the direct fuel injector assembly and its grooves. NOTICE: Do not clean the tip of the direct fuel injector assembly. Do not use a wire brush to clean the direct fuel injector assembly. If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.

*a Area to be Cleaned

(b) Apply engine oil to the direct fuel injector assembly contact surface of SST (guide), and then attach SST (guide) to the direct fuel injector assembly with the chamfer facing the tip of the direct fuel injector assembly as shown in the illustration. SST: 09260-39030 09261-03030

*a SST (Guide) *b Chamfer

(c) Install a new fuel injector seal to SST (holder). SST: 09260-39030 09261-03011 NOTICE: Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal.

*1 Fuel Injector Seal *a SST (Holder) *b Correct *c Incorrect

(d) Install SST (holder) with the fuel injector seal to the tip of the direct fuel injector assembly. Slide the fuel injector seal downward into the direct fuel injector assembly groove with your fingers as shown in the illustration. SST: 09260-39030 09261-03011 09261-03030 HINT: Check that the fuel injector seal is seated in the direct fuel injector assembly groove as shown in the illustration.

*a SST (Holder) *b SST (Guide)

(e) Slowly slide SST (guide) toward the tip of the direct fuel injector assembly. When the direct fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the direct fuel injector assembly groove. SST: 09260-39030 09261-03030 NOTICE: Make sure the fuel injector seal is not pinched between SST (guide) and the edge of the direct fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged. HINT: Set SST (guide) so that its bottom surface is flush with the fuel injector seal. If it is difficult to slide SST (guide) upward, slowly wiggle it from side to side while sliding it up the direct fuel injector assembly little by little.

*a SST (Guide)

(f) After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the direct fuel injector assembly groove. NOTICE: If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one. HINT: Use the same procedure to install the other fuel injector seals.

*a Normal *b Protruding *c Deformed *d Correct *e Incorrect

2. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing a direct fuel injector assembly.

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(a) Install a new injector vibration insulator and a new C-ring to each direct fuel injector assembly. NOTICE: Install the taper of the injector vibration insulator by aligning it with the taper of the direct fuel injector assembly. Check that the C-ring is securely seated in the groove of the direct fuel injector assembly.

*1 Direct Fuel Injector Assembly *2 C-ring *3 Injector Vibration Insulator *a Taper

(b) Install a new O-ring and No. 1 fuel injector back-up ring to each direct fuel injector assembly as shown in the illustration.

(c) With the notch of a new No. 3 fuel injector back-up ring facing downward, install the No. 3 fuel injector back-up ring to each direct fuel injector assembly as shown in the illustration. NOTICE: Make sure that the No. 3 fuel injector back-up ring is installed in the correct orientation. After installing the No. 3 fuel injector back-up ring, make sure there is no damage or foreign matter.

*1 Direct Fuel Injector Assembly *2 No. 3 Fuel Injector Back-up Ring *a Notch

(d) Install the nozzle holder clamp to each direct fuel injector assembly.

(e) Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe and insert the direct fuel injector assembly.

*a	Protrusion
*b	Positioning Hole
	No Gap

3. INSTALL FUEL DELIVERY PIPE

NOTICE:

When replacing the fuel delivery pipe, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

(a) Apply lubricant to the direct fuel injector assembly installation holes of the cylinder head sub-assembly.

(b) Temporarily install the fuel delivery pipe to the cylinder head sub-assembly with the 2 bolts in the order shown in the illustration. NOTICE: If a direct fuel injector assembly is dropped or the tip of a direct fuel injector assembly is struck, replace it with a new one. Check that there is no foreign matter or damage on the direct fuel injector assembly installation holes of the cylinder head sub-assembly. When installing the fuel delivery pipe, push it in evenly without tilting it.

(c) Install the fuel delivery pipe by uniformly tightening the 4 bolts in the order shown in the illustration. Torque: 28.5 N·m {291 kgf·cm, 21 ft·lbf}

(d) Connect the 4 connectors to the 4 direct fuel injector assemblies.

(e) Attach the clamp and connect the fuel pressure sensor.

4. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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5. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

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6. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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7. INSTALL INTAKE MANIFOLD

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8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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9. INSPECT FOR FUEL LEAK

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10. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing a direct fuel injector assembly.

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