Intake Manifold and Fuel System

INTAKE MANIFOLD AND FUEL SYSTEM

REMOVAL AND INSTALLATION

Removal Steps 1-20:

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 tighten, exceeding the specified tightening torque.

1. Completely remove sealant adhering to the oil pressure switch and cylinder block threaded holes.
2. Apply sealant of 5 mm to the threaded portion of the oil pressure switch shown in the illustration.
Specified sealant:
Three bond 1212D, Three bond 1215 or equivalent
3. Tighten the oil pressure switch to the cylinder block to the specified tightening torque.
Tightening 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.
Tightening torque: 20 ± 2 Nm (15 ± 1 ft. lb.)

[C] GENERATOR BRACKET INSTALLATION





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

NOTE: Be careful to install mounting bolts because they are different in length.

[D] INTAKE MANIFOLD INSTALLATION

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

1. Tighten each intake manifold bolt and nut to the temporarily torque.
Temporarily torque: 3.5 ± 1.5 Nm (31 ± 13 in. lb.)
2. Then tighten the intake manifold bolt and nut to specified torque.
Tightening torque: 20 ± 2 Nm (15 ± 1 ft. lb.)

[E] 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 tightening torque.
Tightening torque: 20 ± 2 Nm (15 ± 1 ft. lb.)

[F] O-RING INSTALLATION
1. Apply gasoline to the O-ring.





2. 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.

[G] INJECTOR AND INJECTOR SUPPORT INSTALLATION

CAUTION
Do not allow gasoline to enter the delivery pipe.

1. Apply gasoline to the O-ring of the injector.
2. Insert the injector into the delivery pipe 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 delivery pipe 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 delivery pipe collar.

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





1. Install the delivery pipe assembly, bracket and injector protector rear on the cylinder head.
Temporarily torque: 3.5 ± 11.5 Nm (31 ± 13 in. lb.)
2. Tighten mounting bolts together with temporarily tightened intake manifold mounting bolts in the order shown in the illustration.
3. Tighten the delivery pipe assembly, bracket, injector protector rear and intake manifold in the order shown in the illustration.
Tightening torque: 20 ± 2 Nm (15 ± 1 ft. lb.)