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, Initialisation Procedure for Learning Value in MPI Engine ).
Pre-removal operation
  • Fuel Line Pressure Reduction (Refer to ).
  • Engine Upper Cover Removal (Refer to GROUP 11C - Rocker Cover Assembly ).
  • Air Cleaner Intake Hose Removal (Refer to GROUP 15 - Air Cleaner ).

Post-installation operation
  • Air Cleaner Intake Hose Installation (Refer to GROUP 15 - Air Cleaner ).
  • Fuel Leak Check.
  • Engine Upper Cover Installation (Refer to GROUP 11C - Rocker Cover Assembly ).





Removal steps


·
Control wiring harness connection
<<A>>
>>F<<
1.
Fuel high-pressure hose


·
Emission control vacuum pipe assembly (Refer to GROUP 14A - Water Hose and Water Pipe ).


·
Engine oil level gauge

>>E<<
2.
Injector protector rear

>>E<<
3.
Bracket
<<B>>
>>E<<
4.
Fuel delivery pipe and fuel injector assembly

>>D<<
5.
Fuel injector support

>>C<<
6.
Fuel injector assembly

>>B<<
7.
Fuel injector O-ring

>>A<<
8.
Fuel injector O-ring


9.
Fuel injector


10.
Fuel delivery pipe

REMOVAL SERVICE POINTS



<<A>> FUEL HIGH-PRESSURE HOSE REMOVAL


Follow the steps below to unlock the fuel high-pressure hose connector.



1.Fuel delivery pipe side
(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.
(3) Remove the fuel high-pressure hose.


2.Vehicles side
(1) Remove the stopper of the fuel high-pressure hose.
(2) Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.
note If the retainer is released, install it securely after removing the fuel high-pressure hose.

<<B>> FUEL DELIVERY PIPE AND FUEL INJECTOR ASSEMBLY REMOVAL


caution Do not drop the fuel injector.
Remove the fuel delivery pipe with the fuel injectors attached to it.

INSTALLATION SERVICE POINTS



>>A<< FUEL INJECTOR O-RING INSTALLATION



1.Apply a small amount of petrol to the O-ring.
2.While turning the fuel injector to right and left, install the O-ring to the fuel injector with care to avoid damage to the O-ring.

>>B<< FUEL INJECTOR O-RING INSTALLATION


1.Apply a small amount of petrol oil to the O-ring.

2.Using special tool O-ring installer (MB992106), install the fuel injector paying attention to avoid damage to the O-ring.

>>C<< FUEL INJECTOR ASSEMBLY INSTALLATION


1.Apply a small amount of petrol to the O-ring.

2.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 the installation, check for its smooth rotation. At this time, check that the projection part 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<< FUEL DELIVERY PIPE AND FUEL INJECTOR ASSEMBLY/BRACKET/INJECTOR PROTECTOR REAR INSTALLATION


1.Apply a small amount of petrol to the O-ring at the end of fuel injector assembly.
2.
caution When installing the fuel delivery pipe and fuel injector assembly to the inlet manifold, pay attention to avoid damage to the O-ring at the end of the fuel injector assembly.
Install the fuel delivery pipe and fuel injector assembly to the inlet manifold.
3.Tighten the mounting bolts of the bracket and the injector protector rear loosely.

4.Loosen the inlet manifold mounting nuts and bolts, and the six injector protector front mounting bolts.
5.Loosen the inlet manifold stay mounting bolts (Refer to GROUP 15 - Inlet Manifold ).

6.Tighten the mounting bolts and nuts of the fuel delivery pipe, the bracket, the injector protector and the inlet manifold in the order shown loosely.
Tightening torque: 3.5 ± 1.5 N·m
7.Tighten the mounting bolts and nuts in the order shown to the specified torque.
Tightening torque: 20 ± 2 N·m
8.Tighten the inlet manifold stay mounting bolts (Refer to GROUP 15 - Inlet Manifold ).

>>F<< FUEL HIGH-PRESSURE HOSE INSTALLATION


Follow the steps below to lock the fuel high-pressure hose connector.


1.Fuel delivery pipe side
(1) Pull up the retainer of fuel high-pressure hose to unlock before installing.
(2) Install the fuel high-pressure hose to the fuel delivery pipe.
(3)
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.
Push in the retainer of the fuel high-pressure hose connector to lock the fuel high-pressure hose and fuel delivery pipe.

2.Vehicles side
caution After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 1 mm play. After the check, install the stopper securely.