FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop]

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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 performing work on the fuel system, discharge static electricity by touching the vehicle body.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 2.0 DISI i-stop].)

2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

4.  Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 2.0 DISI i-stop].)

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1	Intake manifold stay
2	High pressure line pipe (See High Pressure Line Pipe Removal Note.) (See High Pressure Line Pipe Installation Note.)
3	Fuel delivery pipe (See Fuel Delivery Pipe Installation Note.)
4	Fuel injector bracket
5	Fuel injector (See Fuel Injector Removal Note.)

High Pressure Line Pipe Removal Note

1.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 2.0 DISI i-stop].)

2.  Disconnect the high pressure line pipe by following procedure.

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(1)  Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.

(2)  Loosen the high pressure line pipe.

3.  Remove the high pressure line pipe.

Fuel Injector Removal Note

Caution

•  Depending on the driving conditions, carbon may accumulate on the inserted part of the fuel injector, causing the fuel injector to sick. 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.

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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.

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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.

Warning

•  If foreign material such as mental 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 hose after removing the fuel injector.

4.  Verify that there are no gasket in the cylinder heads after removing the injectors.

5.  Clean the fuel injector and around the insertion hole using a vacuum cleaner.

Fuel Delivery Pipe Installation Note

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High Pressure Line Pipe Installation Note

1.  Temporarily tighten shown in the figure.

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1	High pressure line pipe installation bolts
2	High pressure line pipe installation nut
3	Water outlet case installation bolt
4	Water outlet case installation bolt

2.  Tighten the high pressure line pipe installation bolts.

3.  Tighten the high pressure line pipe installation nut by following procedure.

(1)  Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.

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(2)  Tighten the high pressure line pipe installation nut.

Tightening torque

24—35 N·m {2.5—3.5 kgf·m, 18—25 ft·lbf}

4.  Tighten the water outlet case installation bolts.