Mitsubishi Outlander 2003-06

Fuel Injectors

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure as described in this section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
  8.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove or disconnect the following:

    Air cleaner
     
    Positive Crankcase Ventilation (PCV) hose
     
    Capacitor connector
     
    Ignition coil connectors
     
    Electrical connector from each injector, label for reference
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Rocker arm (valve) cover bracket bolts
     
    High pressure fuel hose
     
    Bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact.
     
    Injector insulators from the intake manifold, discard. The insulators are not reusable.
     
    Injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.
     

  2.  


    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injectors


To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. Install or connect the following:

    Injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
     
    Fuel rail and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
     
    Engine oil to a new O-ring and install on the high pressure fuel line
     
    High pressure fuel line to the fuel rail. Tighten to 44 inch lbs. (5 Nm).
     
    Rocker arm (valve) cover bracket bolts
     
    EGR valve connector
     
    Fuel injector connectors
     
    Ignition coil connectors
     
    Capacitor connector
     
    PCV hose connector
     
    Negative battery cable
     

  6.  
  7. Pressurize the fuel system and inspect all connections for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  8.  
  9. Remove the fuel rail assembly.
  10.  
  11. Remove the injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.
  12.  

To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. Install the injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Pressurize the fuel system and inspect all connections for leaks.
  10.  

 
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