Intake Manifold and Fuel System Removal and Installation

REMOVAL AND INSTALLATION









- 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 1212D, Three bond 1215 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± 2Nm (89± 17 in-lb)


]]B[[ GENERATOR BRACKET INSTALLATION





Tighten the Generator bracket to the specified torque.
Specified torque: 44± 8Nm (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 inlet manifold because there is a bolt tightening procedure for the inlet manifold, delivery pipe and injector protector.

Install the inlet 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± 2Nm (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 together with temporarily tightened inlet manifold mounting bolts in the order shown in the illustration.
3. Tighten the delivery pipe assembly, bracket, injector protector rear and inlet manifold in the order shown in the illustration.

Temporarily torque: 3.5± 1.5Nm (31± 13 in-lb)
Specified torque: 20± 2Nm (15± 1 ft-lb)