RM38T0EC _51 Engine / Hybrid System _144959 M20F-FXS, M20G-FXS FUEL _0604267 FUEL INJECTOR(for Direct Injection) A

M20F-FXS, M20G-FXS FUEL  FUEL INJECTOR(for Direct Injection)  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A498498N01
1.385,0.521 2.135,0.688 0.75,0.167 1.344,0.479 2.177,0.729 0.833,0.25 1.271,1.354 1.865,1.354 false 4.167,2.583 4.167,2.25 false 1.573,3.604 1.573,3.24 false 4.063,1.271 4.208,0.813 4.208,0.813 4.469,0.813 false 6.344,1.063 6.688,1.063 false 2.906,2.073 2.906,1.927 2.906,1.927 3.156,1.844 false 3.24,2.292 3.24,2.042 3.24,2.042 3.427,1.938 false 3.688,2.469 3.688,2.042 false 4.938,2.417 5.146,2.146 5.146,2.146 5.438,2.146 false 4.646,2.292 4.99,1.802 4.99,1.802 5.24,1.802 false 5.292,2.583 5.667,2.583 false 6.365,0.281 6.708,0.281 false 1.052,0.604 1.385,0.604 false 6.729,0.917 7.083,1.198 0.354,0.281 18 false 10 1.51,3.635 1.792,3.99 0.281,0.354 18 false 9 1.083,1.219 1.365,1.573 0.281,0.354 18 false 8 4.135,2.625 4.417,2.979 0.281,0.354 18 false 7 4.563,0.667 4.844,1.021 0.281,0.354 18 false 6 2.854,2.083 3.135,2.438 0.281,0.354 18 false 5 3.635,2.5 3.917,2.854 0.281,0.354 18 false 4 2.677,2.146 2.958,2.5 0.281,0.354 10 false ● 3.177,2.333 3.479,2.51 0.302,0.177 10 false ● 3.469,2.573 3.906,2.906 0.438,0.333 10 false ● 3.24,1.74 3.677,2.073 0.438,0.333 10 false x4 3.521,1.802 3.958,2.135 0.438,0.333 10 false x4 3.771,1.896 4.208,2.229 0.438,0.333 10 false x4 4.635,2.438 5.073,2.771 0.438,0.333 10 false x4 5.958,2.01 6.24,2.365 0.281,0.354 18 false 3 4.927,2.542 5.365,2.875 0.438,0.333 10 false x4 5.281,2.615 5.719,2.948 0.438,0.333 10 false x4 5.792,2.094 6.229,2.427 0.438,0.333 10 false ● 5.552,1.781 5.99,2.115 0.438,0.333 10 false ● 5.75,1.698 6.031,2.052 0.281,0.354 18 false 2 6.146,2.417 6.427,2.771 0.281,0.354 18 false 1 4.229,2.292 4.667,2.625 0.438,0.333 10 false x4 0.969,0.677 1.406,1.01 0.438,0.333 10 false x4 4.24,1.313 4.677,1.646 0.438,0.333 10 false x4 5.958,2.5 6.396,2.833 0.438,0.333 10 false ● 6.073,0.135 6.438,0.458 0.365,0.323 18 false 11 1.406,0.521 2.25,0.677 0.844,0.156 8 false 28.5 (291, 21)

Procedure Part Name Code
Z101186

Z101188

Z101187

1 FUEL INJECTOR SEAL 23255A (Click here) - -
2 INJECTOR VIBRATION INSULATOR 23291A (Click here) - -
3 C-RING - (Click here) - -
4 NO. 1 FUEL INJECTOR BACK-UP RING 23256 (Click here) - -
5 NO. 3 FUEL INJECTOR BACK-UP RING 23258 (Click here) - -
6 NOZZLE HOLDER CLAMP 23695A - - -
7 DIRECT FUEL INJECTOR ASSEMBLY 23250E (Click here) - -
8 FUEL DELIVERY PIPE 23814B (Click here) - -
9 WIRE HARNESS - - - -
10 FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY 23100X - - -
11 PERFORM INITIALIZATION - - - (Click here)

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) ● Non-reusable part

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.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


PROCEDURE

Hide 23255A 1.INSTALL FUEL INJECTOR SEAL

a.
A459879C03
1.125,3.635 1.375,3.635 false 1.115,3.5 1.406,3.417 false 4.042,0.667 4.292,0.667 false 5.917,0.917 5.917,0.25 false 6.198,0.917 6.198,0.25 6.198,0.25 5.698,0.25 false 4.76,2.49 4.292,2.49 true 4.26,2.885 4.51,2.885 false 0.583,4.917 0.885,4.729 false 1.417,3.542 1.729,3.698 0.313,0.156 10 false *1 0.896,0.375 1.208,0.531 0.313,0.156 10 false *a 3.854,0.573 4.167,0.729 0.313,0.156 10 false *b 5.51,0.146 5.823,0.302 0.313,0.156 10 false *c 1.438,3.302 1.75,3.458 0.313,0.156 10 false *d 4.521,4 4.833,4.156 0.313,0.156 10 false *e 5.521,4 5.833,4.156 0.313,0.156 10 false *f 4.521,5.625 4.76,5.813 0.24,0.188 10 false *g 5.521,5.646 5.76,5.813 0.24,0.167 10 false *h 6.292,5.646 6.542,5.813 0.25,0.167 10 false *i 2.542,2.25 2.854,2.406 0.313,0.156 10 false *f 1.917,2.26 2.229,2.417 0.313,0.156 10 false *e 4.083,2.792 4.396,2.948 0.313,0.156 10 false *b 4.125,2.385 4.438,2.542 0.313,0.156 10 false *d 0.375,4.823 0.688,4.979 0.313,0.156 10 false *b 6.271,4.01 6.583,4.167 0.313,0.156 10 false *f 0.458,0.115 0.74,0.469 0.281,0.354 18 false i 4,0.156 4.281,0.51 0.281,0.354 18 false ii 0.427,1.99 0.708,2.344 0.281,0.354 18 false iii 4.01,2.104 4.292,2.458 0.281,0.354 18 false iv 0.448,4.031 0.677,4.302 0.229,0.271 18 true v 4.042,4.073 4.271,4.344 0.229,0.271 18 true vi
*1 Fuel Injector Seal - -
*a Area to be Cleaned *b SST (Guide)
*c Chamfer *d SST (Holder)
*e Correct *f Incorrect
*g Normal *h Protruding
*i Deformed - -


i.

Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector assembly and its grooves.

NOTICE:
·

Do not clean the tip of the fuel injector assembly.

·

Do not use a wire brush to clean the fuel injector assembly.

·

If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.




ii.

Apply engine oil to the fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the fuel injector assembly with the chamfer facing the tip of the fuel injector assembly as shown in the illustration.

SST
09260-39030  (09261-03030)


iii.

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.



iv.

Install SST (holder) with the fuel injector seal to the tip of the fuel injector assembly. Slide the fuel injector seal downward into the fuel injector assembly groove with your fingers as shown in the illustration.

SST
09260-39030  (09261-03011, 09261-03030)

NOTICE:

Check that the fuel injector seal is seated in the fuel injector assembly groove as shown in the illustration.



v.

Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 10 seconds or more to fully seat the fuel injector seal into the 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 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 fuel injector assembly little by little.




vi.

After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the 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.




Hide 23291A 2.INSTALL INJECTOR VIBRATION INSULATOR

a.
A463655C01
4.667,0.417 5.208,0.417 true 3.146,0.698 3.031,0.427 3.031,0.427 2.781,0.427 false 4.458,1.531 4.042,1.531 false 2.594,0.354 2.906,0.51 0.313,0.156 10 false *1 3.865,1.479 4.146,1.656 0.281,0.177 10 false *2 5.271,0.333 5.583,0.49 0.313,0.156 10 false *a 0.552,0.167 0.833,0.521 0.281,0.354 18 false i
*1 Fuel Injector Assembly *2 Injector Vibration Insulator
*a Taper - -


i.

Install a new injector vibration insulator to each fuel injector assembly.

NOTICE:

Install the taper of the injector vibration insulator by aligning it with the taper of the fuel injector assembly.




Hide 3.INSTALL C-RING

a.
A463319N01
0.469,0.104 0.75,0.458 0.281,0.354 18 false i

i.

Install a new C-ring to each fuel injector assembly.

NOTICE:

Check that the C-ring is securely seated in the groove of the fuel injector assembly.




Hide 23256 4.INSTALL NO. 1 FUEL INJECTOR BACK-UP RING

a.
A461484C03
5.198,1.417 5.604,1.771 true 5.938,1.719 6.281,1.344 true 4.979,1.344 5.292,1.5 0.313,0.156 10 false *1 6.344,1.26 6.656,1.417 0.313,0.156 10 false *2 1.573,0.656 1.885,0.813 0.313,0.156 10 false *a 0.771,1.792 1.083,1.948 0.313,0.156 10 false *b 2.542,1.813 2.854,1.969 0.313,0.156 10 false *c 1.625,1.125 1.938,1.281 0.313,0.156 10 false *d 0.76,1.125 1.073,1.281 0.313,0.156 10 false *e 2.531,1.135 2.844,1.292 0.313,0.156 10 false *e 0.458,0.125 0.74,0.479 0.281,0.354 18 false i
*1 No. 1 Fuel Injector Back-up Ring *2 O-ring
*a No. 1 Fuel Injector Back-up Ring Opening *b Overlapped
*c Stretched *d Correct
*e Incorrect - -


i.

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

NOTICE:
·

Check that there is no foreign matter or damage on the O-ring groove of the fuel injector assembly.

·

Make sure that the No. 1 fuel injector back-up ring is installed in the correct orientation.

·

Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.

·

Check that the opening of the No. 1 fuel injector back-up ring is not overlapped or stretched as shown in the illustration.

·

After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.





Hide 23258 5.INSTALL NO. 3 FUEL INJECTOR BACK-UP RING

a.
A459581C03
4.5,1.25 4.656,1.25 false 4.427,1.948 4.594,1.865 false 4.188,2 4.375,2.26 true 4.698,1.167 5.01,1.323 0.313,0.156 10 false *1 4.625,1.771 4.938,1.927 0.313,0.156 10 false *2 4.344,2.271 4.656,2.427 0.313,0.156 10 false *a 0.479,0.135 0.76,0.49 0.281,0.354 18 false i
*1 Fuel Injector Assembly *2 No. 3 Fuel Injector Back-up Ring
*a Notch - -


i.

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 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.





Hide 23695A 6.INSTALL NOZZLE HOLDER CLAMP

Hide 23250E 7.INSTALL DIRECT FUEL INJECTOR ASSEMBLY

Z101186

NOTICE:

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

Click here(Click here)



a.
A459582C03
3.125,0.365 2.51,0.292 true 3.135,0.49 2.531,0.698 true 2.323,0.208 2.635,0.365 0.313,0.156 10 false *a 2.333,0.635 2.646,0.792 0.313,0.156 10 false *b 0.521,0.156 0.802,0.51 0.281,0.354 18 false i
*a Protrusion *b Positioning Hole
V100135

No Gap - -


i.

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

NOTICE:
·

Make sure that there is no foreign matter or damage inside the direct fuel injector assembly installation holes (fuel delivery pipe).

·

Do not allow gasoline to get on the O-rings or inside the installation holes.

·

If it is difficult to insert the direct fuel injector assembly, apply new engine oil to the chamfer of the direct fuel injector assembly installation hole of the fuel delivery pipe. Be careful not to allow the direct fuel injector assembly to fall out of the fuel delivery pipe.

·

Do not tilt the direct fuel injector assembly when inserting it into the fuel delivery pipe.

·

Check that there is no gap between the fuel delivery pipe and the nozzle holder clamp.

·
A401674C01
1.073,1.656 1.51,1.656 true 1.74,1.646 2.271,1.24 2.271,1.24 2.469,1.24 true 2.521,1.167 2.833,1.323 0.313,0.156 10 false *a 0.906,1.583 1.219,1.74 0.313,0.156 10 false *b
*a QR Code
*b Flow Classification Number


Make sure the 3 direct fuel injector assemblies have the same flow classification number and that the flow classification number is 1, 2, 3, 4, 5, 6, 7, 8 or 9.





Hide 23814B 8.INSTALL FUEL DELIVERY PIPE

Z101186

NOTICE:

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



a.
A467795N01
0.448,0.146 0.646,0.438 0.198,0.292 18 false i 4.021,0.125 4.219,0.417 0.198,0.292 18 false ii 0.458,2.083 1.24,2.365 0.781,0.281 18 true iii, iv, v 1.229,2.448 1.385,2.625 0.156,0.177 10 true A 2.74,2.406 2.896,2.583 0.156,0.177 10 true B 0.667,2.448 0.844,2.625 0.177,0.177 10 true C 3.271,2.385 3.448,2.563 0.177,0.177 10 true C 3.99,2.125 4.188,2.417 0.198,0.292 18 false vi 4.802,2.427 4.958,2.604 0.156,0.177 10 true 1 6.313,2.427 6.469,2.604 0.156,0.177 10 true 2 4.229,2.417 4.396,2.625 0.167,0.208 10 true 3 6.865,2.385 7.031,2.594 0.167,0.208 10 true 4

i.

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


ii.

Temporarily install the fuel delivery pipe to the cylinder head sub-assembly.

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.




iii.

Temporarily install the bolt (A).


iv.

Temporarily install the bolt (B).


v.

Temporarily install the 2 bolts (C).


vi.

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)



Hide 9.CONNECT WIRE HARNESS

Hide 11.PERFORM INITIALIZATION

a.

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

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION