7GR-FKS FUEL  FUEL INJECTOR(for Direct Injection)  INSTALLATION  

0.74,0.406 1.052,0.563 0.313,0.156 10 false *a

*a	Clean Area

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.

0.917,1.188 1.083,0.708 1.083,0.708 1.167,0.708 false 2.167,0.896 2.583,0.896 2.583,0.896 2.583,1.729 false 2.25,1.729 2.25,0.896 false 1.219,0.625 1.531,0.781 0.313,0.156 10 false *a 2,0.813 2.313,0.969 0.313,0.156 10 false *b

*a	SST (Guide)
*b	Tapered Inner Portion

Apply engine oil to the direct fuel injector assembly contact surface of SST (guide), 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

09260-39021  (09261-03020)

0.99,2.635 1.49,2.635 false 1.01,2.802 1.396,3.042 1.396,3.042 1.49,3.042 false 1.531,2.563 1.729,2.76 0.198,0.198 10 false *a 2.771,0.563 2.969,0.76 0.198,0.198 10 false *c 1.979,0.552 2.177,0.75 0.198,0.198 10 false *b 1.542,2.969 1.74,3.167 0.198,0.198 10 false *1

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

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

SST

09260-39021  (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 and correcting this problem is very complicated.

0.781,1.177 0.927,0.531 0.927,0.531 1.094,0.531 true 0.979,1.75 1.094,1.969 1.094,1.969 1.208,1.969 true 1.135,0.448 1.448,0.604 0.313,0.156 10 false *a 1.25,1.896 1.563,2.052 0.313,0.156 10 false *b

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

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

SST

09260-39021  (09261-03011, 09261-03020)

HINT:

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

0.594,1.333 0.781,0.458 0.781,0.458 0.885,0.458 true 0.938,0.375 1.25,0.531 0.313,0.156 10 false *a

*a	SST (Guide)

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

09260-39021  (09261-03020)

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.

0.563,2.729 0.765,2.927 0.202,0.198 10 *a 1.795,2.729 1.997,2.927 0.202,0.198 10 *b 2.752,2.729 2.954,2.927 0.202,0.198 10 *c 0.569,0.498 0.771,0.696 0.202,0.198 10 *d 2.711,0.498 2.914,0.696 0.202,0.198 10 *e 1.772,0.498 1.974,0.696 0.202,0.198 10 *e

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

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.

1.052,0.427 1.229,0.427 1.229,0.427 1.51,0.927 false 2.302,0.396 2.479,0.396 2.479,0.396 2.615,0.635 false 2.531,0.208 2.708,0.208 2.708,0.208 2.844,0.448 false 2.885,0.094 3.01,0.094 3.01,0.094 3.01,0.49 true 0.865,0.365 1.177,0.521 0.313,0.156 10 false *1 2.115,0.323 2.427,0.479 0.313,0.156 10 false *2 2.354,0.135 2.667,0.292 0.313,0.156 10 false *3 2.708,0.01 3.021,0.167 0.313,0.156 10 false *a

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

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.

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

5.917,1.708 6.208,1.135 6.208,1.135 6.354,1.135 true 4.99,1.188 5.208,1.188 5.208,1.188 5.625,1.781 true 4.781,1.104 5.094,1.26 0.313,0.156 10 false *1 6.417,1.052 6.729,1.208 0.313,0.156 10 false *2 1.583,0.563 1.896,0.719 0.313,0.156 10 false *a 0.76,1.875 1.073,2.031 0.313,0.156 10 false *b 2.552,1.875 2.865,2.031 0.313,0.156 10 false *c 1.604,1.073 1.917,1.229 0.313,0.156 10 false *d 0.76,1.073 1.073,1.229 0.313,0.156 10 false *e 2.531,1.063 2.844,1.219 0.313,0.156 10 false *e

*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	-	-

NOTICE:

·

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

3,2.188 2.927,2.188 2.927,2.188 2.74,2.375 false 3.031,1.438 2.979,1.438 2.979,1.438 2.854,1.573 false 2.479,2.448 2.729,2.813 2.729,2.813 2.823,2.813 true 3.052,1.354 3.24,1.573 0.188,0.219 10 false *1 3.052,2.125 3.24,2.344 0.188,0.219 10 false *2 2.844,2.729 3.031,2.906 0.188,0.177 10 false *a

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

With the notch of a new No. 3 fuel injector back-up ring facing downward, install each direct fuel injector assembly to the No. 3 fuel injector back-up ring 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.

2.156,0.542 2.677,0.188 2.677,0.188 2.823,0.188 true 2.219,0.833 2.646,1.073 2.646,1.073 2.792,1.073 true 2.875,0.104 3.188,0.26 0.313,0.156 10 false *a 2.854,0.99 3.167,1.146 0.313,0.156 10 false *b

*a	Protrusion
*b	Positioning Hole
	No Gap

Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, 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 with sensor assembly LH and fuel delivery pipe RH).

·

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 with sensor assembly LH and fuel delivery pipe RH. Be careful not to allow the direct fuel injector assembly to fall out of the fuel delivery pipe with sensor assembly LH or fuel delivery pipe RH.

·

Do not tilt the direct fuel injector assembly when inserting it into the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.

·

Check that there is no gap between the fuel delivery pipe with sensor assembly LH, fuel delivery pipe RH and the nozzle holder clamp.

·

1.073,1.604 1.573,1.604 true 1.823,1.583 2.323,1.25 2.323,1.25 2.49,1.25 true 2.552,1.177 2.865,1.333 0.313,0.156 10 false *a 0.896,1.531 1.208,1.688 0.313,0.156 10 false *b

*a	QR Code
*b	Flow Classification Number

Install 3 direct fuel injector assemblies with the same flow classification number (the number to the left of the QR code which is 6, 7 or 8) on each bank (6 fuel injector assemblies with the same flow classification number is also okay).

2,0.635 2.313,0.792 0.313,0.156 10 false *a

*a	Nut can be attached

Insert the stud bolt into the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.

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 RH, push it in evenly without tilting it.

0.521,1.51 0.75,1.698 0.229,0.188 10 true *1 0.531,1.885 0.729,2.063 0.198,0.177 10 true *2 2.844,0.063 3.073,0.24 0.229,0.177 10 true *a 1.219,0.427 1.385,0.604 0.167,0.177 10 true 1 2.406,1.01 2.573,1.188 0.167,0.177 10 true 2 3.135,1.333 3.302,1.51 0.167,0.177 10 true 4 0.552,0.271 0.719,0.448 0.167,0.177 10 true 3

*1	Bolt
*2	Nut
*a	Front

Install the fuel delivery pipe RH by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

Torque:

26 N*m (265 kgf*cm, 19 ft.*lbf)

2,0.635 2.313,0.792 0.313,0.156 10 false *a

*a	Nut can be attached

Insert the stud bolt into the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.

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 LH.

·

When installing the fuel delivery pipe with sensor assembly LH, push it in evenly without tilting it.

0.521,1.51 0.729,1.688 0.208,0.177 10 true *1 0.531,1.885 0.729,2.063 0.198,0.177 10 true *2 2.833,0.042 3.052,0.24 0.219,0.198 10 true *a 1.635,0.542 1.792,0.719 0.156,0.177 10 true 1 2.573,0.969 2.75,1.135 0.177,0.167 10 true 2 3.198,1.198 3.365,1.375 0.167,0.177 10 true 4 0.646,0.25 0.802,0.427 0.156,0.177 10 true 3

*1	Bolt
*2	Nut
*a	Front

Install the fuel delivery pipe with sensor assembly LH by uniformly tightening the 2 bolts and 2 nuts in the order shown in the illustration.

Torque:

26 N*m (265 kgf*cm, 19 ft.*lbf)

1.667,0.573 1.979,0.729 0.313,0.156 10 false *a

*a	Torque Wrench Fulcrum Length

Using a 17 mm union nut wrench, tighten the 2 union nuts of the No. 2 fuel pipe sub-assembly.

Torque:

Specified tightening torque : 35 N*m (357 kgf*cm, 26 ft.*lbf)

NOTICE:

·

If the 2 union nuts cannot be fastened, loosen the nuts of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, and then fasten both union nuts.

·

Do not adjust the torque in the loosening direction.

·

The No. 2 fuel pipe sub-assembly can be reused 10 times.

HINT:

·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201902,999999,_V1,_078841,_0382392,RM100000001GTX7,

·

When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

·

This torque value is effective when the union nut wrench is parallel to the torque wrench.

·

Install the union nut wrench parallel with the torque wrench.