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 (Three bond 1215, Three bond 1212D or equivalent) of 5 mm (0.2 inch) 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] KNOCK SENSOR INSTALLATION





Align the knock sensor connector with the position shown in the illustration, and then tighten it to the specified torque.
Specified torque: 20 ± 2 Nm (15 ± 1 ft-lb)

[C] 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: 23 ± 6 Nm (17 ± 4 ft-lb)

[D] O-RING INSTALLATION





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.

[E] INJECTOR / O-RING / INJECTOR SUPPORT INSTALLATION

CAUTION:
Do not allow gasoline to enter the fuel rail.

1. Apply 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.

[F] FUEL RAIL ASSEMBLY INSTALLATION
1. Apply gasoline to the pressure side O-ring of the injector.
2. Tighten the fuel rail assembly to the intake manifold to the specified torque.
Specified torque: 12 ± 3 Nm (106 ± 26 in-lb)

[G] FUEL PRESSURE REGULATOR INSTALLATION
1. Apply gasoline to the new O-ring.

CAUTION:
Do not allow gasoline to enter the fuel rail.

2. Insert the fuel pressure regulator into the fuel rail while rotating the injector from side to side, taking care not to damage the O-ring.
3. Check that the fuel pressure regulator rotates smoothly. If it does not rotate smoothly, the O-ring may be caught. Remove the fuel pressure regulator and check the O-ring for damage. Then, insert it again into the fuel rail and check.