Fuel Injector: Service and Repair
FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]
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 the "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.
NOTE:
- When the fuel pressure sensor replaces, replace a new fuel delivery pipe with a new fuel pressure sensor.
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 intake manifold. Service and Repair
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution
High Pressure Line Pipe Removal Note
1. Drain the engine coolant. Service and Repair
2. Disconnect the high pressure line pipe of the high pressure fuel pump. High Pressure Fuel Pump Removal/Installation
a. Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
b. Loosen the high pressure line pipe installation nut.
3. Remove the high pressure line pipe.
Fuel Injector Removal Note
NOTE:
- Depending on the driving conditions, carbon may accumulate on the inserted part of the fuel injector, causing the fuel injector to stick. Remove the fuel injector using the following procedure.
1. Install the SST to the fuel injector confirming that the SST faces the correct direction as shown in the figure.
CAUTION:
- If the SST slips while ratcheting up the fuel injector, the fuel injector or surrounding parts could be damaged. Press fit the SST to the fuel injector firmly and operate carefully.
- When ratcheting up the fuel injector, the fuel injector connector may contact the cylinder head and damage the fuel injector. Ratchet up the fuel injector so that the fuel injector connector does not contact the cylinder head.
NOTE:
- If fuel injector No.3 contacts the oil separator, cut the tab on the oil separator as shown in the figure. Carefully cut the tab so that the oil separator is not deformed or damaged, with no clearance on the mating surfaces of the oil separator and engine.
2. Keep ratcheting the SST so that the fuel injector becomes free enough to ratchet up without using the SST.
CAUTION:
- Do not apply excessive force to the fuel injector connector because the fuel injector could be damaged.
3. Pull out the fuel injector by ratcheting it upright.
4. Verify that there are no gasket in the cylinder heads after removing the fuel injectors.
WARNING:
- If foreign material such as metal shavings penetrates the fuel injector installation hole on the cylinder block, the engine could be damaged. Remove all foreign material and cap the fuel injector installation hole after removing the fuel injector.
5. Clean the fuel injector and around the insertion hole using a vacuum cleaner.
Fuel Delivery Pipe Installation Note
1. Tighten the bolts in the order shown in the figure.
Tightening torque
- 17-23 Nm {1.8-2.3 kgf-m, 13-16 ft-lbf}
High Pressure Line Pipe Installation Note
1. Temporarily tighten the bolts in the order shown in the figure.
2. Tighten bolts of No.1 shown in the figure.
Tightening torque
- 17-23 Nm {1.8-2.3 kgf-m, 13-16 ft-lbf}
3. Tighten high pressure line pipe installation nut of No.2 shown in the figure.
a. Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
b. Tighten the high pressure line pipe installation nut.
Tightening torque
- 24-35 Nm {2.5-3.5 kgf-m, 18-25 ft-lbf}
4. Tighten bolts of No.3, No.4 shown in the figure.
Tightening torque
- 8-11 Nm {82-112 kgf-cm, 71-97 in-lbf}