Fuel Injector: Service and Repair

INJECTOR

REMOVAL AND INSTALLATION

CAUTION: When the fuel injector is replaced, initialize the learned value using scan tool (Refer to Precautions before Service - Initialization Procedure for Learning Value in MFI Engine)










Required Special Tool:
- MB992106: O-ring Installer

REMOVAL SERVICE POINTS

[[A]] FUEL HIGH-PRESSURE HOSE DISCONNECTION







1. Follow the steps below to unlock the fuel high-pressure hose connector.







1. Insert a flat-tipped screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04inch) thick] into the retainer of the fuel high-pressure hose connector.

CAUTION: When pushing up the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.







2. Turn the flat-tipped screwdriver inserted into the retainer by 90 degree angle to push up the retainer and unlock the fuel high-pressure hose connector.

2. Disconnect the fuel high-pressure hose.

[[B]] FUEL RAIL AND FUEL INJECTOR ASSEMBLY REMOVAL

CAUTION: Do not drop the fuel injector.

Remove the fuel rail with the fuel injectors attached to it.

INSTALLATION SERVICE POINTS

]]A[[ O-RING INSTALLATION







1. Apply a small amount 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 small amount of new engine oil to the O-ring.







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

]]C[[ FUEL INJECTOR ASSEMBLY INSTALLATION

CAUTION: When applying the engine oil, make sure not to allow the engine oil to enter the fuel rail inside.

1. Apply a small amount of new engine oil to the O-ring.







2. Turning the fuel injector assembly to right and left, install it to the fuel rail 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 center.
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 rail and check for its smooth rotation.

]]D[[ FUEL INJECTOR SUPPORT INSTALLATION







Install the fuel injector support to the fuel injector groove and fuel rail brim, and fix the fuel injector assembly and fuel rail.

]]E[[ FUEL RAIL AND FUEL INJECTOR ASSEMBLY/BRACKET/INJECTOR PROTECTOR REAR INSTALLATION

CAUTION: When applying the engine oil, make sure not to allow the engine oil to enter the intake manifold inside.

1. Apply a small amount of new engine oil to the O-ring at the end of fuel injector assembly.

CAUTION: When installing the fuel rail and fuel injector assembly to the intake manifold, pay attention to avoid damage to the O-ring at the end of the fuel injector assembly.

2. Install the fuel rail and fuel injector assembly to the intake manifold.
3. Tighten the mounting bolts of the bracket and the injector protector rear loosely.







4. Loosen the four mounting bolts and nuts of the intake manifold.
5. Remove the EGR valve.
6. Loosen the EGR valve support and intake manifold coupling bolts.
7. Loosen the intake manifold stay mounting bolts.







8. Temporarily tighten the mounting bolts of the fuel rail, and the mounting bolts and nuts of the bracket, injector protector rear, and intake manifold to the specified torque in the order of number shown in the figure.

Tightening torque: 3.5 ± 1.5 N.m (31 ± 13 in-lb)

9. Temporarily tighten the mounting bolts of the fuel rail, and then mounting bolts and nuts of the bracket, injector protector rear, and intake manifold to the specified torque in the order of number shown in the figure.

Tightening torque: 20 ± 2 N.m (15 ± 1 ft-lb)

10. Tighten the intake manifold stay mounting bolts.
11. Tighten the EGR valve support and intake manifold coupling bolts to the specified torque.
12. Install the EGR valve.

]]F[[ FUEL HIGH-PRESSURE HOSE CONNECTION







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







2. Securely insert the fuel rail stopper into the fuel high-pressure hose connector groove to install the fuel high-pressure hose to the fuel rail.

CAUTION:
- When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
- After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.

3. Push in the retainer of the fuel high-pressure hose connector to lock the fuel high-pressure hose and fuel rail.