Intake Manifold and Fuel System Removal and Installation

REMOVAL AND INSTALLATION









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[[ 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.

]]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.

Tighten each inlet manifold bolt and nut to the temporarily torque of 3.5 ± 1.5 Nm (31 ± 13 in-lb).

]]D[[ INLET MANIFOLD STAY INSTALLATION





Make sure that the inlet manifold stay is in intimate contact with the inlet manifold and cylinder block boss before tightening it to the specified tightening torque.
Tightening torque: 20 ± 2 Nm (15 ± 1 ft-lb)


]]E[[ 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.

]]F[[ INJECTOR AND INJECTOR SUPPORT INSTALLATION

1.
CAUTION:
Do not allow gasoline to enter the delivery pipe.

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.

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





1. Install the delivery pipe assembly, bracket and injector protector rear 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 ± 1.5 Nm
(31 ± 13 in-lb)
Specified torque: 20 ± 2 Nm (15 ± 1 ft-lb)