Intake Manifold and Fuel System

INTAKE MANIFOLD AND FUEL SYSTEM

REMOVAL AND INSTALLATION

Removal Steps 1-22:

Required Special Tool:
^ MB992106: O-ring Installer

INSTALLATION SERVICE POINTS

]]A[[ ENGINE OIL PRESSURE SWITCH INSTALLATION





CAUTION
^ Do not allow sealant to squeeze out to the screw tip.
^ Do not exceed the specified torque.

1. Completely remove sealant adhering to the engine oil pressure switch and cylinder block threaded holes.
2. Apply sealant (LOCTITE 565 or equivalent) of 5 mm to the threaded portion of the engine oil pressure switch shown in the illustration.
3. Tighten the engine oil pressure switch to the cylinder block to the specified torque.

Specified torque: 10 ± 2 Nm (89 ± 17 in-lb)

]]B[[ GENERATOR BRACKET INSTALLATION





Tighten the Generator bracket to the specified torque.
Specified torque: 44 ± 8 Nm (33 ± 5 ft-lb)

NOTE: Be careful when install mounting bolts as they are different in length. See illustration for bolt locations.

]]C[[ INTAKE MANIFOLD INSTALLATION

CAUTION
Temporarily tighten the intake manifold because there is a bolt tightening procedure for the intake manifold, fuel rail and injector protector.

Install the intake manifold and temporarily tighten bolts.

]]D[[ INTAKE MANIFOLD STAY INSTALLATION





Make sure that the intake manifold stay is in intimate contact with the intake manifold and cylinder block boss before tightening it to the specified torque.

Specified torque: 20 ± 2 Nm (15 ± 1 ft-lb)

]]E[[ O-RING INSTALLATION

CAUTION
Do not allow engine oil to enter the fuel rail.





When inserting an O-ring into the injector on the injection nozzle side, use special tool MB992106 to gradually expand the O-ring and fit it in place.

]]F[[ INJECTOR AND INJECTOR SUPPORT INSTALLATION
1. Apply spindle oil or gasoline to the O-ring of the injector.
2. Insert the injector into the fuel rail while rotating the injector from side to side, taking care not to damage the O-ring
3. Check that the injector rotates smoothly. If it does not rotate smoothly, the O-ring may be caught. Remove the injector and check the O-ring for damage. Then, insert it again into the fuel rail and check.





4. Make sure that the protrusion of the injector is at the center as shown in the illustration.





5. Securely assemble the injector to the injector groove and fuel rail collar.

]]G[[ FUEL RAIL ASSEMBLY / BRACKET / INJECTOR PROTECTOR REAR INSTALLATION





1. Install the fuel rail assembly, bracket and injector protector on the cylinder head.
2. Tighten mounting bolts to the specified torque together with temporarily tightened intake manifold mounting bolts in the order shown in the illustration.

Specified torque: 20 ± 2 Nm (15 ± 1 ft-lb)