Fuel Injector: Service and Repair

REMOVAL AND INSTALLATION













Required Special Tool:

- MB992106: O-ring installer

REMOVAL SERVICE POINTS

[[A]] FUEL HIGH-PRESSURE HOSE DISCONNECTION





1.
CAUTION:
Do not kink the fuel high-pressure hose as it is made of plastics.

Insert a flat-tipped screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04inch) 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.
3. Disconnect the fuel high-pressure hose.

[[B]] FUEL RAIL AND 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[[ O-RING INSTALLATION





1. Apply a small amount of new engine oil 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[[ O-RING INSTALLATION

1. Apply a small amount of new engine oil to the O-ring.





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

]]C[[ FUEL INJECTOR ASSEMBLY INSTALLATION

1.
CAUTION:
When applying the engine oil, make sure not to allow the engine oil to enter the fuel rail inside.

Apply a small amount of new engine oil 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 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 flange, and fix the fuel injector assembly and fuel rail.

]]E[[ FUEL RAIL AND FUEL INJECTOR ASSEMBLY INSTALLATION

1.
CAUTION:
When applying the engine oil, make sure not to allow the engine oil to enter the intake manifold inside.

Apply a small amount of new engine oil 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 fuel rail mounting bolts to the specified torque.
Tightening torque: 12 ± 1 Nm (106 ± 8 in-lb)


]]F[[ FUEL HIGH-PRESSURE HOSE CONNECTION





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





2.
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 (0.04inch) play.

Install the fuel high-pressure hose to the fuel rail securely and push retainer of the fuel high-pressure hose connector downward and lock thoroughly.