Fuel Injector: Service and Repair

REMOVAL AND INSTALLATION













- 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 (0.04 inch) thick]
into the retainer of the fuel high-pressure hose connector.
(2)

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

Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees 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[[
FUEL INJECTOR O-RING INSTALLATION

1. Apply a small amount of gasoline 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[[
FUEL INJECTOR O-RING INSTALLATION

1. Apply a small amount of gasoline to the O-ring.





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

]]C[[
FUEL INJECTOR ASSEMBLY INSTALLATION

1. Apply a small amount of gasoline 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 part 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

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

2.
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.

Install the fuel rail and fuel injector assembly to the intake manifold.

3. Tighten the mounting bolts of the bracket and the protector loosely.





4. Loosen the four mounting bolts and nuts of the intake manifold.
5. Remove the EGR valve [ Service and Repair].
6. Loosen the EGR valve stay and intake manifold coupling bolts [ Service and Repair].
7. Loosen the intake manifold stay mounting bolts Service and Repair).





8. Tighten the mounting bolts and nuts of the fuel rail, the bracket, the protector and the intake manifold in the order shown loosely.
Tightening torque: 3.5± 1.5Nm (31± 13 in-lb)
9. Tighten the mounting bolts and nuts in the order shown to the specified torque.
Tightening torque: 20± 2Nm (15± 1 ft-lb)
10. Tighten the intake manifold stay mounting bolts Service and Repair).
11. Tighten the EGR valve stay and intake manifold coupling bolts to the specified torque [ Service and Repair].
12. Install the EGR valve [ Service and Repair].

]]F[[
FUEL HIGH-PRESSURE HOSE CONNECTION





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





2. 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.