REMOVAL AND INSTALLATION

caution

When the injector replacement is performed, use the M.U.T.-III to initialise the learning value (Refer to GROUP 00, Precautions Before Service - Initialisation Procedure for Learning Value in MPI Engine

Pre-removal Operation

Fuel Line Pressure Reduction (Refer to ).
Surge tank Removal (Refer to GROUP 15 - Inlet Manifold ).

Post-installation Operation

Surge tank Installation (Refer to GROUP 15 - Inlet Manifold ).
Fuel Leak Check

			Removal steps
<<A>>	>>E<<	1.	Fuel high-pressure hose connection
		2.	Fuel injector connector
<<A>>	>>E<<	3.	Fuel high-pressure hose connection
<<B>>		4.	Fuel delivery pipe and injector assembly
		5.	Insulators
	>>D<<	6.	Fuel injector support
		7.	Fuel delivery pipe L.H.
	>>C<<	8.	Fuel injector assembly
		9.	Fuel injectors
	>>B<<	10.	O-ring
	>>A<<	11.	O-ring
		·	Cooling water outlet pipe (Refer to GROUP 14, Water Hose and Water Pipe ).
		12.	Fuel injector connector
<<B>>		13.	Fuel delivery pipe and injector assembly
		14.	Insulators
	>>D<<	15.	Fuel injector support
		16.	Fuel delivery pipe R.H.
	>>C<<	17.	Fuel injector assembly
		18.	Fuel injectors
	>>B<<	19.	O-ring
	>>A<<	20.	O-ring

REMOVAL SERVICE POINTS

<<A>> FUEL HIGH-PRESSURE HOSE DISCONNECTION

caution

Do not kink the fuel high-pressure hose as it is made of plastics.

Insert a flat-tipped screwdriver (width 6 mm, thickness 1 mm) to the retainer.

2.Turn the flat-tipped screwdriver approximately 90° to the arrowed direction, and lift the retainer to unlock and disconnect the fuel high-pressure hose.

<<B>> FUEL DELIVERY PIPE AND INJECTOR ASSEMBLY REMOVAL

caution

Do not drop the fuel injector.

Remove the fuel delivery pipe with the fuel injectors attached to it.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION

1.Apply a drop 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 drop of new engine oil to the O-ring.
2.Using special tool O-ring installer (MB992106), install the O-ring to the fuel injector paying attention to avoid damage to the O-ring.

>>C<< FUEL INJECTOR ASSEMBLY INSTALLATION

caution

Do not let the engine oil get into the delivery pipe.

Apply a drop of new engine oil to the O-ring.

2.Turning the fuel injector assembly to right and left, install it to the delivery pipe 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 centre.
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 delivery pipe and check for its smooth rotation.

>>D<< FUEL INJECTOR SUPPORT INSTALLATION

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

>>E<< FUEL HIGH-PRESSURE HOSE CONNECTION

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

2.Install the fuel high-pressure hose to the delivery pipe securely and push the lock of fuel high-pressure hose downward and lock thoroughly.
3.After installing, slightly pull the fuel high-pressure hose and ensure that there is no disengaged fuel high-pressure hose. Also confirm that there is approximately 1 mm play at this time.