FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

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  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.
  • The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the service record when removing and installing the fuel injection pipe. If removing it for the sixth time, be sure to replace it with a new one.
  • When replacing any one injector with no circle mark in the calibration code with one that does have a circle mark, always replace the other three injectors with injectors having a circle mark at the same time and perform PCM reprogramming.

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  Note
  • If the fuel injector is replaced, always perform each adjustment procedure using the following steps.
  • When replacing any injector with no circle mark in the calibration code with one that does, the other three injectors with no circle mark need to be replaced at the same time.

STEP | ACTION | PAGE/CONDITION
--- | --- | ---
1 | Replace the fuel injector. | –
2 | Turn the engine switch on. | –
3 | Perform PCM reprogramming* | (See PCM REPROGRAMMING [MZR-CD (RF Turbo)].)
4 | Perform fuel injector code program procedure. | (See FUEL INJECTOR CODE PROGRAM [MZR-CD (RF Turbo)].)
5 | Perform fuel injector data reset procedure. | (See FUEL INJECTOR DATA RESET [MZR-CD (RF Turbo)].)
6 | Turn the engine switch off. | –
7 | Wait for 20 s. | –
8 | Start the engine. | Verify that the MIL dose not illuminate.
9 | Turn the engine switch off. | –
10 | Turn the engine switch on (Engine off). | –
11 | Perform KOEO self-test procedure. | (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
12 | Start the engine. | –
13 | Perform KOER self-test procedure. | Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2, EXHTEMP3 PID) is 100 °C {212 °F} or more. (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
14 | Perform 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 ENGINE TUNE-UP [MZR-CD (RF Turbo)].)
15 | Turn the engine switch off. | –

* :Only when replacing any one injector with no circle mark in the calibration code with one that does have a circle mark.

1. Disconnect the negative battery cable.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD (RF Turbo)].)

  Note
  • When removing/installing the cylinder head cover, an injector seal may be damaged by a fuel injector connector. “Refer to CYLINDER HEAD COVER REMOVAL/INSTALLATION”. (See CYLINDER HEAD GASKET REPLACEMENT [MZR-CD (RF Turbo)].)

3. Remove the cylinder head cover. (See CYLINDER HEAD GASKET REPLACEMENT [MZR-CD (RF Turbo)].)

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

6. Install the cylinder head cover. (See CYLINDER HEAD GASKET REPLACEMENT [MZR-CD (RF Turbo)])

7. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD (RF Turbo)].)

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1 | Fuel leak pipe (See Fuel Leak Pipe Installation Note.)
2 | Injection pipe (See Injection Pipe, Injection Bracket Installation Note.)
3 | Nozzle seal (See Injection Pipe, Injection Bracket Installation Note.)
4 | Side wall (See Injection Pipe, Injection Bracket Installation Note.)
5 | Injector bracket (See Injection Pipe, Injection Bracket Installation Note.)
6 | Fuel injector

Injection Pipe, Injection Bracket Installation Note

1. Install the side wall.

2. Install the nozzle seal.

3. Temporarily tighten the injection pipes.

4. Temporarily tighten the injector bracket.

  Tightening torque

  10—20 N·m {1.1—2.0 kgf·m, 7.4—14.8 ft·lbf}

5. Tighten the injector side injection pipes.

  Tightening torque

  40—50 N·m {4.1—5.0 kgf·m, 30—36 ft·lbf}

6. Tighten the common rail side injection pipes.

  Tightening torque

  40—50 N·m {4.1—5.0 kgf·m, 30—36 ft·lbf}

7. Tighten the injector bracket.

  Tightening torque

  52—62 N·m {5.4—6.3 kgf·m, 39—45 ft·lbf}

Fuel Leak Pipe Installation Note

1. Tighten the fuel leak pipe installation bolts in the order shown in the figure.

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  Tightening torque

  19.2—23.4 N·m {1.96—2.38 kgf·m, 14.2—17.2 ft·lbf}