Fuel Injector: Service and Repair

FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]

WARNING:
- Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE PRECAUTION".
- A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

CAUTION:
- Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

2. Remove the battery cover. Removal and Replacement

3. Disconnect the negative battery cable. Removal and Replacement

4. Remove the plug hole plate. Plug Hole Plate Removal/Installation

5. Disconnect the fuel injector connector.

6. Remove in the order indicated in the table.










7. Install in the reverse order of removal.

8. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution

Fuel Injector Clip Removal Note

CAUTION:
- Use of a deformed fuel injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage. It will also cause the fuel injector to rotate. Therefore, always replace the clip when the fuel injector is removed.

1. Insert a flathead screwdriver between the fuel injector cup and clip finger.






NOTE:
- When pushing the clip finger outward, deform the finger until it is removed completely from the cup notch.






2. Push the clip finger outward using a flathead screwdriver.

3. Remove the fuel injector with the clip.

4. Remove the clip from the fuel injector using the following procedure:

CAUTION:
- The clip will not be reused.

a. Hold the clip using pliers.

b. Pull the clip parallel to the fuel injector groove and remove it from the fuel injector.






Fuel Injector Installation Note

1. Apply a small amount of clean oil to the fuel injector groove and the new O-ring, and assemble them.

2. Temporarily attach a new clip to the fuel injector groove.
NOTE:
- When the clip is attached correctly, the central area of the fuel injector and the clip finger positions are aligned.

3. Hold the fuel injector firmly and push the clip into the fuel injector until the clip stops sliding.






4. Verify that the fuel injector connector position is correct.

5. Press the fuel injector into the fuel injector cup. Continue pressing until the clip contacts the lower surface of the fuel injector cup.

6. Verify that the fuel injector and clip are correctly installed with the clip locked onto the fuel injector cup notch.