REMOVAL AND INSTALLATION


caution When the fuel injector is replaced, initialise the learned value using M.U.T.-III (Refer to GROUP 00 - Precautions before Service, and Initialisation Procedure of MPI Engine Learned Value ).
Pre-removal operation
  • Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) (Refer to ).
  • Engine Upper Cover Removal (Refer to GROUP 16 - Ignition System, Ignition Coil ).
  • Intercooler Intake Air Hose A and Intercooler Outlet Air Hose Removal (Refer to GROUP 15 - Intercooler ).

 Post-installation operation
  • Intercooler Intake Air Hose A and Intercooler Outlet Air Hose Installation (Refer to GROUP 15 - Intercooler ).
  • Fuel Leak Check
  • Engine Upper Cover Installation (Refer to GROUP 16 - Ignition System, Ignition Coil ).




Removal steps


1.
 Control wiring harness connection


2.
 Fuel return hose connection


3.
 PCV hose


4.
 Emission control equipment hose connection
<<A>>
 >>F<<
 5.
 Fuel high-pressure hose connection


6.
 Engine upper cover bracket rear


7.
 Fuel injector hose


8.
 Fuel injector return pipe

>>E<<
 9.
 Fuel pressure regulator

>>E<<
 10.
 O-ring


11.
 Fuel delivery pipe and fuel injector assembly


12.
 Fuel delivery pipe insulator

>>D<<
 13.
 Fuel injector support

>>C<<
 14.
 Fuel injector assembly

>>B<<
 15.
 O-ring

>>A<<
 16.
 O-ring


17.
 Fuel injector


18.
 Fuel delivery pipe

REMOVAL SERVICE POINT

<<A>> FUEL HIGH-PRESSURE HOSE DISCONNECTION



1.Follow the steps below to unlock the fuel high-pressure hose connector.
(1) Insert a flat-tipped screwdriver (6 mm wide and 1 mm thick) into the retainer of the fuel high-pressure hose connector.
(2)
caution When pushing up the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel high-pressure hose connector.
2.Remove the fuel high-pressure hose.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION

1.Apply a small amount of new engine oil to the O-ring.
2.While turning the fuel injector to right and left, install the O-ring to the fuel injector with care not to damage the O-ring.

>>B<< O-RING INSTALLATION
1.Apply a small amount of new engine oil to the O-ring.

2.Using special tool O-ring installer (MB992106), install the O-ring to the fuel injector with care not to damage the O-ring.

>>C<< FUEL INJECTOR ASSEMBLY INSTALLATION
1.
caution When applying the engine oil, do not let the engine oil get into the fuel delivery pipe inside.
Apply a small amount of new engine oil to the O-ring.

2.While turning the fuel injector assembly to right and left, install it to the fuel delivery pipe with care not to damage the O-ring. After installing, check for its smooth rotation. At this time, check that the projection of the fuel injector assembly is in the centre.
3.If the rotation is not smooth, the O-ring may be caught. Remove the fuel injector assembly and check the O-ring for damage. After this, re-insert it to the fuel delivery pipe and check for its smooth rotation.

>>D<< FUEL INJECTOR SUPPORT INSTALLATION

Install the fuel injector support to the fuel injector groove and fuel delivery pipe brim, and fix the fuel injector assembly and fuel delivery pipe.

>>E<< O-RING/FUEL PRESSURE REGULATOR INSTALLATION
1.Apply a small amount of new engine oil to the O-ring.
2.Turning the fuel pressure regulator to right and left, install it to the fuel delivery pipe with care not to damage the O-ring. After the installation, check for its smooth rotation.
note If the rotation is not smooth, the O-ring may be caught. Remove the part and check the O-ring for damage. After this, re-insert it to the fuel delivery pipe and check for its smooth rotation.
3.Tighten the fuel pressure regulator mounting bolts to the specified torque.
Tightening torque: 8.5 ± 3.5 N·m

>>F<< FUEL HIGH-PRESSURE HOSE CONNECTION

1.
caution
  • When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
  • After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm play.
Securely insert the fuel delivery pipe stopper into the fuel high-pressure hose connector groove to install the fuel high-pressure hose to the fuel delivery pipe.
2.Push in the retainer of the fuel high-pressure hose connector to lock the fuel high-pressure hose and fuel delivery pipe.