FEPAIR INSTRUCTIONS, PART 1

Betore Busing añ i.jector, cle inq js rsquiréd to €nsure suilability tor éuse. Berc're doing ar'y c éaning, rhe injelor tuel inlel and oullel ports ánd lh6 el€crical connec¡or opening musl be covered lo prdé¡l dnlminarion lrom lhe cl4ning pfo@ss- Also, lh€ré musl be no Lower o{ing ¡¡sialled ¡n lhe lnlecior Relérto'uNlT INJEoToF oLEANING'on pag6 244 lor

Ren@ lhe boe proieolion deM, 9S94251.

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FiquÉ 270Unft rn¡dor Borc PEr€dion sre#

1 uni¡ lnlsdo' Prcrdion lr.'rnirlnlebeE

4. lnlallñ6w O{ings on lhe unil injecloras

. Upper nnS larSé dlamelor, viol¿l

. Lower ring smalldlañ6i6r, violál

5. Lubr¡€¡e boih Ojlngs and fis cyl nd¿r head inj¿cror boré wilh clean eng¡ne o¡1. hstarr a ñe inieclio¡ noz e gaskel {ital washer) on the i¡jéclor, usinq hand lorce to push il @. lhe l¡p and down uñii it is fully seated againsr lhé bofiom ot the injecror Do NOT use géas6 or any olher nale a¡ lo secure lhe gaskel to lhe ¡¡jetor the gskér ñust bé inslalled dry Three sñal pojections (srippé6) on rhe inside dlameler ot lhis gaskel rctaiñ il to ih€ injéclor during

Somé ea y pbduclion MP3 engines ced lhe orjginal design copp€r déms with iniegEl laised bead ar rhe bonom or rhe copper sr66vé. rhis désign doés NOT use a gaskel llat washeD between lhe ¡njecior tip 5nd the @pper slewe, These oriqinal Eised¡ead d6lon copD6r sledescan b€ idénrir ed by a single groo@, orno gbove al all around ih8 upp¿r circumie¡ence, The curent prod uclion 'flal-botom' design @pper sle4esi wh¡ch reqúi€ me gask€t (llat sásher) ár lhé iniécrór rip¡ can be identmed by lwo groov€ áround th¿ uppér circunle¡en@ ol

Note

A rwied g4kel (llal washeo havinq a lhln blac( rubber maling for impMd séaling was implemenled ln pbductlon begln¡lng ñld-auqusl 2003. Serul.e replacement qaskels n@ have ihe rubber coaling, DO NOT remove lhe rubber

The qaskel (llal washer) is p€assembled on new

7, SLip lhe injécior hold d@n and á n4 srew of cor€ct l6ñoth oñlo lhe lnll ¡nieolol

10. Ensure rhar thé i¡jdtor érécld€r @nllecbr is @ntEl betreen thé hh€ springd wilh €qual space on borh sides. ll rhe hañess is insiállod, pluq in lhé ¡njecior electrical @nnector únlll tully enqag¿d. Push in the @nnec!o. unlil you hear a diliñct'tlicl\¡.

1 nltuf Nod DM %k I 2 udrhFdr

Make sue that lhe inletor ts einstatted lo lhé same cylinderfom which il Ms reñóred (or inieclor lrim óds will need lo be rep@gEmmed h ihe EEcu).

Cenler lhe un¡l ¡njector ben@en tha Elvé sp nqs and rhen plsh down on the lnf inj¿clor using hand pre$¡re lo seal lhe O rings. Hand lighlén lhé nil hold-down

NOTE

Fioue274-Erd c¡rconn*brbrunnh,¿dór

11. Using á lorqué w€nch, l¡ghlen lhe hold dowñ scéw in daqés to speflicarion.

12_ When Éplacjhg lnil ini€clo6, lhe @nlol unil musl be prcqrammed silh lh6 .s injécro/s ldm @des, The code is plnled on lop olthé unit injector élécl cal.onneotol The prcgrammi¡O ls péfom€d 6inq vCADSm and is ne@ssary lo ensub lhál 8ñqiné limina and emission levels aé