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22MY / L200/L200 SPORTERO / Europe/Russia (Eastern Europe countries) - Workshop Manual

13 -FUEL > 13A-DIESEL FUEL > FUEL INJECTOR > > FUEL INJECTOR REMOVAL AND INSTALLATION<4N15>

REMOVAL AND INSTALLATION <4N15>

When the fuel injector assembly is replaced, register the fuel injector identification code and
caution perform the small injection quantity learning (Refer to GROUP 00 – Precautions before Service,
What the Common Rail Engine Learns ).
Pre-removal Operation Post-installation Operation

Engine Cover, Injector Upper Insulator and

Injector Lower Insulator Removal (Refer to Fuel Line Leak Check (Refer to )
Engine Cover, Injector Upper Insulator and
GROUP 11A – Engine Assembly ). Injector Lower Insulator Installation (Refer to

GROUP 11A – Engine Assembly ).

Removal
13
7 10 steps
8 12
7 10
1. Control
12 11 N
11 N wiring
7 10 harness
12 Front:1.1 ± 0.1 N·m,
7 9
Rear:+180° ± 1° 2. Harness
then Front: +90° ± 1°
N 11 bracket
18 ± 2 N·m then 35 ± 5 N·m
3. Fuel
N 11 (Engine oil) >>A<< injection
N 14 pipe No. 1
15
6 N 1
4. Fuel
16
5N
>>A<< injection
pipe No. 2
4 N
N 17 5. Fuel
N 3 11 ± 3 N·m
>>A<< injection
2 pipe No. 3
6. Fuel
>>A<< injection
pipe No. 4
7. Joint clip
26 ± 6 N·m 8. Fuel return
ACF00257 AB line hose C
and fuel
injection
tube joint
assembly
9. Fuel
injection
tube joint
A
 Removal
steps
10. Fuel
injection
tube joint
B
11. O-ring
12. Fuel return
line hose C
13. Fuel return
line hose C
connection
14. Fuel
>>A<< injector
washer
15. Fuel
>>A<< injector
holder
16. Fuel
<<A>> >>A<< injector
assembly
17. Fuel
<<B>> injector
nozzle
gasket

REMOVAL SERVICE POINTS

<<A>> FUEL INJECTOR ASSEMBLY REMOVAL

Always reinstall the fuel injector assembly to the cylinder from

caution
which it has been removed.

<<B>> FUEL INJECTOR NOZZLE GASKET REMOVAL

MB992333
MB992333

Fuel
injector
nozzle
gasket

AC809000 AB

1. Insert the special tool nozzle gasket remover (MB992333) to the fuel
injector assembly mounting hole on the cylinder head.
2. Rotate the dial of the tool as shown, and then pull out the tool while
holding the fuel injector nozzle gasket.
 INSTALLATION SERVICE POINT

>>A<< FUEL INJECTOR ASSEMBLY/FUEL INJECTOR

HOLDER/FUEL INJECTOR WASHER/FUEL INJECTION PIPE NO.
4/FUEL INJECTION PIPE NO. 3/FUEL INJECTION PIPE NO.
2/FUEL INJECTION PIPE NO. 1 INSTALLATION

Fuel injector

A: Nozzle side face

Injection part of the nozzle AC900270 AB

Fuel injector

AC900203 AB

Cylinder head

MB990784
AC900204 AB

1. Clean the fuel injector assembly (nozzle) and the cylinder head (fuel
injector assembly mounting hole) by following the procedure below.
(1)
caution Do not clean the injection part of the nozzle with a resin spatula.
Using a resin spatula, scrape off the carbon deposit on the fuel injector
nozzle side face ("A" shown in the figure).
(2) Spray the carburettor cleaner (MITSUBISHI MOTORS GENUINE Part No.
MZ100139 or equivalent) to the nozzle side face ("A" shown in the figure).
(3)
Do not touch the injection part of the nozzle with hand or wipe it
caution
with a rag.
Leave the injection part for a while until the carbon deposit melts down, and
then blow air to the injection part.
(4) Insert the special tool ornament remover (MB990784) to the cylinder
head (fuel injector assembly mounting hole) with turning the special tool as
shown, and scrape off the carbon deposit.
(5)
 In order to prevent carbon from adhering to the inner surface of
caution
the cylinder, blow air with the piston in the TDC position.
Remove the special tool MB990784, and blow off the carbon deposit on the
cylinder head (fuel injector assembly mounting hole) by air.
(6) Check that there is no carbon deposit remaining on the contact surface
of the fuel injector nozzle gasket.
Repeat Step (4) to Step (6) several times until the carbon
note
deposit is completely removed.
2. Replace the fuel injector nozzle gasket with a new one.
3.

If the removed fuel injector assembly to be reinstalled

cannot be identified, register the fuel injector identification
code and perform the small injection quantity learning.
caution (Refer to GROUP 00 – Precautions before Service, What

the Common Rail Engine Learns ).

Securely insert the fuel injector assembly.

Install the fuel injector assembly.

4. Apply an adequate and minimum amount of engine oil to the thread of
the fuel injector holder bolts, the lower area of the flange, and fuel injector
washer.
Steel scale

Fuel injector
assembly
Fuel injector holder bolt ACI02866 AB

5. Put the steel scale on the upper flat part of the fuel injector assembly to
make horizontal axis as shown in the illustration.
Steel scale

Fuel
injector Fuel injector
holder Fuel injector holder bolt
bolt assembly ACI02865 AB

6. Measure the height of fuel injector holder bolts located on the front and
rear side of fuel injector holder against the horizontal axis, then check that
the difference of the measured values is within 2 mm.
It is not necessary to adjust all the fuel injector holder bolts to
note be the same height. Each 2 bolts of fuel injector assembly need
to be the same height.
7. Mount the fuel injection pipe No. 1 to No. 4 and temporarily install them.
8. Tighten the bolt on the engine front side of the fuel injector holder bolts
to 1.1 ± 0.1 N·m.
MB991614

AC809088 AB

9. Use the special tool angle gauge (MB991614) to tighten the engine rear
side bolts of the fuel injector holder to 180 ± 1 degree angle.
10. Use the special tool MB991614 to tighten the engine front side bolts of
the fuel injector holder to 90 ± 1 degree angle.
11.

The removed fuel injection pipe can be reassembled up to

five times. To count the number of fuel injection pipe
reassembly, record it by adding the reassembly number of
this time (once usually) to the previous number of
reassembly written on the maintenance handbook. When
the number of the previous reassembly reaches 5 or when
the fuel injector assembly or common rail assembly is
replaced, always use a new fuel injection pipe. At that
time, write "New (0 times)" in the maintenance handbook.
If a fuel leak is present in the fuel injection pipe and fuel
caution injection pipe set once, do not reuse it and replace with a
new one.
If the fuel injector assembly, common rail assembly or
supply pump assembly is replaced, the contact surface
(seal surface) between the fuel injection pipe and fuel
injection pipe set, and the other side component is
changed, do not reuse the fuel injection pipe and fuel
supply pump pipe and replace with a new one.
When reassembling the fuel injection pipe, remove the
foreign material attached on the sealing surface, and
install it with the contacting point of the pipe aligned.

Loosen the install bolt of the common rail assembly, and the flare nut of the

supply pump pipe (Refer to ).

12. Align the fuel injection pipe centre axis with the other side components
(common rail assembly and fuel injector assembly) centre axis to install the
fuel injection pipe No. 1 to No. 4. Then, tighten the flare nut temporarily until
the tip of pipe (seal surface) contacts with the other side components.
When the fuel injection pipe is installed, tighten the flare nut
note while shaking the pipe lightly to align the centre axis of both
components.

MB992211

AC809093 AB

13. Using the special tool crowfoot wrench (MB992211), tighten the
common rail assembly side of the fuel injection pipe No. 1 to No. 4 to the
temporary tightening torque calculated by the following formula.
Tightening torque: (18 ± 2) × {L ÷ (L + 25)} N·m
 18 ± 2: Temporary tightening torque of the fuel injection pipe (unit:
N·m)
L: Distance between the centre of a torque wrench drive and of its
handle (unit: mm)
25: Length of pitch for special tool between holes (unit: mm)
14. Using the special tool crow foot wrench (MB992211), tighten the
common rail assembly side of the fuel injection pipe No. 1 to No. 4 to the
specified torque calculated by the following formula.
Tightening torque: (35 ± 5) × {L ÷ (L + 25)} N·m

35 ± 5: Tightening torque of the fuel injection pipe (unit: N·m)

L: Distance between the centre of a torque wrench drive and of its
handle (unit: mm)
25: Length of pitch for special tool between holes (unit: mm)

15. Tighten the install bolt of the common rail assembly, and the flare nut of

the supply pump pipe. (Refer to .)

16. Check that no fuel is leaked from the fuel injection pipe connection area
and the gasket.
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