REMOVAL AND INSTALLATION


caution When the injector replacement is performed, use the M.U.T.-III to initialise the learning value (Refer to GROUP 00, Precautions Before Service - Initialisation Procedure for Learning Value in MPI Engine ).
Pre-removal Operation
  • Fuel Discharge Prevention (Refer to ).
  • Surge tank Removal (Refer to GROUP 15 - Inlet Manifold ).

 Post-installation Operation
  • Surge tank Installation (Refer to GROUP 15 - Inlet Manifold ).
  • Fuel Leakage Inspection.




Removal steps
<<A>>
 >>E<<
 1.
 Fuel high-pressure hose connection


2.
 Fuel injector connector
<<A>>
 >>E<<
 3.
 Fuel high-pressure hose connection
<<B>>
4.
 Fuel delivery pipe and injector assembly


5.
 Insulators

>>D<<
 6.
 Fuel injector support


7.
 Fuel delivery pipe left

>>C<<
 8.
 Fuel injector assembly


9.
 Fuel injectors

>>B<<
 10.
 O-ring

>>A<<
 11.
 O-ring


·
 Cooling water outlet pipe (Refer to GROUP 14, Water Hose and Water Pipe ).


12.
 Fuel injector connector
<<B>>
13.
 Fuel delivery pipe and injector assembly


14.
 Insulators

>>D<<
 15.
 Fuel injector support


16.
 Fuel delivery pipe right

>>C<<
 17.
 Fuel injector assembly


18.
 Fuel injectors

>>B<<
 19.
 O-ring

>>A<<
 20.
 O-ring

REMOVAL SERVICE POINTS

<<A>> FUEL HIGH-PRESSURE HOSE DISCONNECTION

1.
caution Be careful not to twist the fuel high-pressure hose because it is made of resin.
Insert the (-) driver or similar tool (width: 6 mm, thickness: 1 mm) to the retainer of the fuel high-pressure hose connector.

2.Turn the (-) driver inserted into the retainer by 90 degrees, push up the retainer, and then unlock the fuel high-pressure hose connector.
3.Disconnect the fuel high-pressure hose from the fuel delivery pipe.

<<B>> FUEL DELIVERY PIPE AND 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<< O-RING INSTALLATION

1.Apply a drop 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 to avoid damage to the O-ring.

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

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

>>C<< FUEL INJECTOR ASSEMBLY INSTALLATION
1.
caution Do not let the engine oil get into the delivery pipe.
Apply a drop of new engine oil 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 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 the fuel delivery pipe.

>>E<< FUEL HIGH-PRESSURE HOSE CONNECTION

1.Pull up the lock of fuel high-pressure hose to unlock before installing.

2.
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.
Install the fuel high-pressure hose to the fuel delivery pipe securely and push the lock of fuel high-pressure hose downward and lock thoroughly.