1G
Fuel Injector Removal and Installation
Reference: Fuel Injector On-Vehicle Inspection:K9K
NOTE:
The calibration code (1) is the code that is given to each fuel injector, and it represents the performance characteristics of the fuel injector. It is registered in ECM, and ECM controls fuel injection according to the performance characteristics of the fuel injector. Therefore, after removing fuel injectors, be sure to install them as they were. In case that the fuel injectors were replaced with new ones, be sure to register each calibration code in ECM referring to ECM Registration:K9K . If it is not registered correctly, DTC is stored in ECM and warning light is turned ON. Also calibration codes registration in ECM can be checked by SUZUKI scan tool.
Removal
1) Check that engine is cold and fuel pressure is not under pressure referring to Fuel Pressure Relief Confirmation Procedure:K9K .
2) Disconnect negative (–) cable at battery.
3) Remove injector cover.
4) Disconnect fuel injector connector (1).
5) Disconnect return hose (2) from fuel injector.
6) Plug fuel return pipe of fuel injector with cap available as a spare part to prevent them from entering dust. (Refer to “Precaution” under Fuel Delivery System Description:K9K for parts number and handling.)
7) Remove high pressure pipe referring to High Pressure Pipes Removal and Installation:K9K .
8) Remove fuel injector (1) from cylinder head.
9) Remove searing washer from cylinder head hole.
10) Plug fuel injector nozzle with cap available as a spare part to prevent them from entering dust. (Refer to “Precaution” under Fuel Delivery System Description:K9K for parts number and handling.)
Installation
1) Clean fuel injector installing hole of cylinder head, fuel injector body and fuel injector bracket using a lint-free cloth dipped in clean solvent.
2) Remove plug (dust preventing cap) (1) from fuel injector nozzle.
3) Install new searing washer to cylinder head.
4) Install fuel injector to cylinder head.
Tighten fuel injector bracket bolt to specified torque.
Tightening torque
Fuel injector bracket bolt ( a ): 28 N·m ( 2.8 kg-m, 20.5 lb-ft)
5) Install new high pressure pipe referring to High Pressure Pipes Removal and Installation:K9K .
6) Remove plug (dust preventing cap) (1) from fuel return pipe of fuel injector.
7) Connect return hose (2) to fuel injector.
8) Connect fuel injector connector (1).
9) Install injector cover.
10) Connect negative (–) cable to battery.
11) Check fuel leakage referring to Fuel Leakage Check:K9K .