FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2]

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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 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
•  Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags to soak up the fuel.
•  To prevent the fuel injection pipe from clogging, be careful that foreign material has not entered the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the fuel injection pipe.
•  To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing and installing the fuel injector.
Note
•  If the fuel injector is replaced, always perform each adjustment procedure using the following steps.

STEP

ACTION

PAGE/CONDITION
1
Replace the fuel injector.
–
2
Switch the ignition to on.
–
3
Perform fuel injector code program procedure.
(See FUEL INJECTOR CODE PROGRAM [MZR-CD 2.2].)
4
Perform fuel injector data reset procedure.
(See FUEL INJECTOR DATA RESET [MZR-CD 2.2].)
5
Switch the ignition to off.
–
6
Wait for 20 s.
–
7
Start the engine.
Verify that the MIL does not illuminate.
8
Switch the ignition to off.
–
9
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
10
Start the engine.
–
11
Perform KOER self-test procedure.
Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2 PID) is 100 °C {212 °F} or more.
(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
12
Perform fuel injector injection amount correction procedure.
Engine coolant temperature 65—95 °C {149—203 °F}.
Intake air temperature 15—65 °C {59—149 °F}.
Fuel temperature 30—60 °C {86—140 °F}.
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [MZR-CD 2.2].)
13
Switch the ignition to off.
–

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Disconnect the following parts and set the fuel injector wiring harness out of the way.

•  Fuel injector connector
•  Boost sensor connector
•  Fuel pressure sensor connector
•  EGR cooler bypass valve control solenoid valve connector
•  Front harness-short cord connector
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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-CD 2.2].)

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1
Injection pipe (fuel injector side)
2
Fuel return hose
3
Fuel injector bracket
4
Fuel injector
(See Fuel Injector Installation Note.)


Fuel Injector Installation Note

1.  Verify that the oil seal is not damaged.

•  If damaged, replace the oil seal. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR-CD 2.2].)

Note
•  If the nozzle end is damaged, nozzle breakage or abnormal injection due to nozzle hole damage could occur. In addition, if the injector washer seal surface is damaged, combustion gas leakage could occur. To prevent these problems from occurring, do not allow the nozzle end and seal surface to come into contact with a hard object.

2.  Completely wipe off any foreign matter (such as oil, sludge) from the injector outer periphery, washer seal surface, and the injector installation hole.

3.  Install the fuel injector.

4.  Temporarily tighten the injection pipe (fuel injector side).

5.  Temporarily tighten the fuel injector bracket.

6.  Temporarily tighten the nut A.

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Temporary tightening torque
0.5—1.5 N·m {5.1—15 kgf·cm, 4.5—13 in·lbf}

7.  Temporarily tighten the nut B.

Temporary tightening torque
1.5—2.5 N·m {16—25 kgf·cm, 14—22 in·lbf}

8.  Tighten nuts A and B to the specified angle using the following procedure so that the total tightening angle is between 87°—93°.

1.  Tighten nut A to the specified angle.
Tightening angle
Approx. 45°
2.  Tighten nut B to the specified angle.
Tightening angle
Approx. 45°
3.  Further tighten nut A to the specified angle.
Tightening angle
Approx. 45°
4.  Further tighten nut B to the specified angle.
Tightening angle
Approx. 45°

9.  Tighten the injection pipe (fuel injector side).

Tightening torque
30—40 N·m {3.1—4.0 kgf·m, 23—29 ft·lbf}