FI32

EFI SYSTEM Fuel System

Injector

REMOVAL OF RH INJECTORS
1. 2. 3. 4. 5. 6. 7. 8. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY REMOVE AIR CLEANER WITH AIR FLOW METER (See steps 1 to 3 on page FI48) REMOVE THROTTLE BODY (See steps 2 to 6 on pages FI52, 53) REMOVE RH AND LH ENGINE WIRE COVERS REMOVE RH AND LH NO.3 TIMING BELT COVERS REMOVE RH IGNITION COIL (See step 4 on page FI66) REMOVE LOWER HIGHTENSION CORD COVER REMOVE ENGINE WIRE (a) Remove the two bolts and disconnect the engine wire from the delivery pipe. (b) Disconnect the following connectors: Water temp. sender gauge connector Water temp. sensor connector Start injector time switch connector Four injector connectors DISCONNECT FOLLOWING FUEL PIPES AND TUBE: (a) Fuel return pipe (b) Cold start injector tube (c) Front fuel pipe

9.

FI33
EFI SYSTEM Fuel System

10. REMOVE REAR FUEL PIPE Remove the two union bolts and four gaskets, then remove the rear fuel pipe. HINT: Leave rear fuel pipe on vehicle.

11. REMOVE DELIVERY PIPE WITH INJECTOR (a) Pull vacuum hose out of pressure regulator. (b) Remove the two nuts and remove the delivery pipe with injectors. (c) Remove the four insulators from the intake manifold.

12. REMOVE INJECTORS FROM DELIVERY PIPE

FI34
EFI SYSTEM Fuel System

REMOVAL OF LH INJECTORS
1. 2. 3. 4. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY DRAIN COOLANT (See step 3 on pages CO5, 6) DISCONNECT NO.1 PCV HOSE REMOVE UPPER HIGHTENSION CORD COVER AND LH ENGINE WIRE COVER DISCONNECT FOLLOWING HOSES: (a) Three vacuum hoses from vacuum pipe (b) Four vacuum hoses from air pipe (c) Two vacuum hoses from VSV for EGR (d) EGR vacuum modulator hose from EGR valve REMOVE EGR VACUUM MODULATOR AND VCV WITH BRACKET (a) First remove the bolt, and then remove the EGR vacuum modulator and VCV with bracket. DISCONNECT CHECK CONNECTOR FROM BRACKET REMOVE TWO VSVS (a) Disconnect the connectors from the two VSVs. (b) Remove the two bolts and the two VSVs.

5.

6.

7. 8.

9.

REMOVE NO.3 AND NO.4 WATER BYPASS PIPES

10. DISCONNECT ENGINE WIRE (a) Remove the two bolts and disconnect the engine wire from the delivery pipe. (b) Disconnect the following connectors: Distributor connector Engine speed sensor connector EGR gas temp. sensor connector Four injector connectors

FI35
EFI SYSTEM Fuel System

11. DISCONNECT FUEL INLET HOSE Remove the bolt, pulsation damper and two gaskets, and disconnect the fuel inlet hose from the delivery pipe.

12. DISCONNECT FRONT FUEL PIPE 13. REMOVE REAR FUEL PIPE (See step 10 on page FI33) 14. REMOVE DELIVERY PIPE WITH INJECTORS (See step 11 on page FI33) 15. REMOVE INJECTORS FROM DELIVERY PIPE

FI36
EFI SYSTEM Fuel System

INSPECTION OF INJECTOR
1. MEASURE RESISTANCE OF INJECTOR Using an ohmmeter, measure the resistance between the terminals.
Resistance: 13.414.2 W at 20C (68F)

If the resistance is not as specified, replace the injector.

2.

INSPECT INJECTOR INJECTION CAUTION: Keep injectors clear of sparks during the test. (a) Remove the pressure regulator. (See page FI30 when inspecting RH injectors) (See pages FI29, 30 when inspecting LH injectors)

(b) Disconnect the fuel inlet hose from the fuel tube. (c) Connect SST (Union) and SST (Hose) to the fuel tube. SST 0926841045 (0926852010)

(d) Install SST (Union) and SST (Hose) to the removed pressure regulator. SST 0926841045 (0926852010) (e) Install SST (Union) and two new gaskets to the pressure regulator with union bolt. SST 0926841045 (0926841070) (f) Connect the fuel return hose to SST (Union).

(g) Install SST (Union) to the injector, then install SST (Clamp) to the injector and union. SST 0926841045 (h) Connect SST (Hose) to union. SST 0926841045

FI37
EFI SYSTEM Fuel System

(i)

Install the injector inside the graduated cylinder. HINT: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out.

(j) Connect cable to the negative terminal of battery. (k) Turn the ignition switch ON. HINT: Do not start the engine. (l) Using SST, connect terminals FP and +B of the check connector. SST 0984318020 HINT: The fuel pump will operate.

(m) Install SST (Wire) to the injector, and connect to battery for 15 seconds. Measure the injection volume with a graduated cylinder. Test each injector two or three times. SST 0984230070
Injection volume: 55 70 cc/15 sec. (3.4 4.3 cu in.) Difference between each injector: Less than 10 cc (0.6 cu in.)

If the injection is not as specified, replace the injector. 3. INSPECT LEAKAGE (a) In the condition above, disconnect SST from the battery and check the fuel leakage from the injector nozzle. Fuel drop: One drop or less per three minutes

(b) Disconnect cable from the negative terminal of battery. (c) Remove SST from the injector. (d) Remove SST from the check connector. 4. 5. CONNECT FUEL INLET HOSE TO FUEL MAIN TUBE
Torque: 35 Nm (358 kgfcm, 26 ftlbf)

INSTALL PRESSURE REGULATOR (See page FI31)

FI38
EFI SYSTEM Fuel System

INSTALLATION OF RH INJECTORS
1. INSTALL INJECTORS INTO DELIVERY PIPE (a) Install the grommet and a new Oring to the injector.

(b) Apply a light coat of gasoline to each Oring and install the injectors into the delivery pipe.

(c) Check that the injectors rotate smoothly. HINT: If an injector does not rotate smoothly, the probable cause is incorrect installation of the Oring. Replace the O ring.

2.

INSTALL DELIVERY PIPE WITH INJECTORS Install the four insulators in the injector installation holes in the intake manifold.

(a) Install the injectors together with the delivery pipe in the intake manifold. (b) Install and temporarily tighten the two nuts.

FI39
EFI SYSTEM Fuel System

(c)

Check that the injectors rotate smoothly to the left and right. HINT: If an injector does not rotate smoothly, the probable cause is incorrect installation of Orings. Remove the injector again and replace the Oring.

3.

TEMPORARILY INSTALL REAR FUEL PIPE Temporarily install the rear fuel pipe to the RH and LH delivery pipes with four new gaskets and two union bolts. TEMPORARILY INSTALL FRONT FUEL PIPE Temporarily install the front fuel pipe to the RH and LH delivery pipes with four new gaskets and two union bolts. TIGHTEN DELIVERY PIPE, FRONT AND REAR FUEL PIPES Torque the delivery pipe first, then front and rear fuel pipes.
Torque: Delivery pipe Front fuel pipe Rear fuel pipe 18 Nm (185 kgfcm, 13 ftlbf) 39 Nm (400 kgfcm, 29 ftlbf) 39 Nm (400 kgfcm, 29 ftlbf)

4.

5.

6.

CONNECT COLD START INJECTOR TUBE AND FUEL RETURN PIPE Connect the cold start injector tube and fuel return pipe with union bolt and new gaskets.
Torque: Cold start injector tube 15 Nm (150 kgfcm, 11 ftlbf) Fuel return pipe 35 Nm (360 kgfcm, 26 ftlbf)

7.

CONNECT ENGINE WIRE (a) Connect the following connectors: Four injector connectors Start injector time switch connector Water temp. sensor connector Water temp. sender gauge connector (b) Install the engine wire to the delivery pipe with the two bolts.
Torque: 8.3 Nm (85 kgfcm, 74 in.lbf)

FI40
EFI SYSTEM Fuel System

8. 9.

INSTALL LOWER HIGHTENSION CORD COVER INSTALL RH IGNITION COIL (See step 2 on page FI67)

10. INSTALL RH AND LH NO.3 TIMING BELT COVERS 11. INSTALL RH AND LH ENGINE WIRE COVERS 12. INSTALL THROTTLE BODY (See steps 2 to 7 on pages FI56, 57) 13. INSTALL AIR CLEANER WITH AIR FLOW METER (See steps 2 to 4 on page FI49) 14. FILL WITH COOLANT (See step 3 on pages CO5, 6) 15. INSTALL CABLE TO NEGATIVE TERMINAL OF BATTERY 16. CHECK FOR FUEL AND COOLANT LEAKAGE Start the engine and check for fuel or coolant leakage. 17. CHECK COOLANT LEVEL (See step 1 on page CO5)

FI41
EFI SYSTEM Fuel System

INSTALLATION OF LH INJECTORS
1. 2. INSTALL INJECTORS TO DELIVERY PIPE (See step 1 on page FI38) TEMPORARILY INSTALL DELIVERY PIPE WITH INJECTORS (See step 2 on pages FI38, 39) TEMPORARILY INSTALL REAR FUEL PIPE (See step 3 on page FI39) TEMPORARILY INSTALL FRONT FUEL PIPE (See step 4 on page FI39) TIGHTEN DELIVERY PIPE, FRONT AND REAR FUEL PIPES (See step 5 on page FI39)

3. 4. 5.

6.

CONNECT FUEL INLET HOSE Install the fuel inlet hose to the delivery pipe with two new gaskets, pulsation damper and bolt.
Torque: Pulsation damper 39 Nm (400 kgfcm, 29 ftlbf) Bolt 7.8 Nm (80 kgfcm, 69 in.lbf)

7.

CONNECT ENGINE WIRE (a) Connect the following connectors: Four injector connectors EGR gas temp. sensor connector Engine speed sensor connector Distributor connector (b) Install the engine wire to the delivery pipe with the two bolts.
Torque: 8.3 Nm (85 kgfcm, 74 in.lbf)

8.

INSTALL NO.3 AND NO.4 WATER BYPASS PIPES

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EFI SYSTEM Fuel System

9.

INSTALL TWO VSVS (a) Install the two VSVs.

Torque: 18 Nm (185 kgfcm, 13 ftlbf)

(b) Connect the connectors. 10. INSTALL CHECK CONNECTOR

11. INSTALL EGR VACUUM MODULATOR AND VCV WITH BRACKET (a) Install the EGR vacuum modulator and VCV with bracket and the bolt. 12. CONNECT FOLLOWING HOSES: (a) EGR vacuum modulator hose to EGR valve (b) Two vacuum hoses to VSV for EGR (c) Four vacuum hoses to air pipe (d) Three vacuum hoses from vacuum pipe 13. INSTALL UPPER HIGHTENSION CORD COVER AND LH ENGINE WIRE COVER 14. CONNECT NO.1 PCV HOSE 15. FILL WITH COOLANT (See step 3 on pages CO5, 6) 16. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 17. CHECK FOR FUEL AND COOLANT LEAKAGE Start the engine and check for fuel or coolant leakage. 18. CHECK COOLANT LEVEL (See step 1 on page CO5)