wankermini

Fuel Injector System

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tagspajero-mini, service-manual, ch5

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Fuel Injector System

Injector testing procedure (printed p.137)

  1. Locate the injectors.
  2. Start the engine and warm to operating temperature.
  3. Use a stethoscope and listen to each injector for a “ticking” sound. If an injector is dead (no ticking), note its related cylinder. Test all injectors.
  4. Remove injector connectors and test connectivity as previously explained.
    • Ohm range: 13-16 Ω @ 20°C (68°F). Check against ECU spec. Remove defective injectors for further bench testing.
  5. Set up the individual-injector test rig from the fuel pressure regulator: fuel inlet line, hose adapter MD998741, injector test set MD998706 with clip MD998746, fuel injector, fuel pressure regulator, return line, adapter MD999603. Use a jumper wire (as in the Fuel Line Pressure Test) to run the fuel pump.
  6. Using adapter MD998706, apply direct (+)/(-) connectivity to engage the injector. If the injector fails to spray fuel, it must be replaced.

Note: if the vehicle has over 100,000 km (62,137 mi) and one injector has failed, all injectors in the set must be replaced together.

Figure: Fuel Injector testing setup and stethoscope check

Component removal (printed p.138)

Component removal order, fuel rail assembly:

  1. Accelerator Cable
  2. Vacuum Hose
  3. Fuel Return Line
  4. Fuel Pipe
  5. Fuel Rubber Hose
  6. Fuel Pressure Regulator
  7. O-Ring
  8. Fuel Inlet High Pressure Hose
  9. O-Ring
  10. Injector Electrical Connector
  11. Fuel Rail
  12. Insulator Grommet
  13. Grommet
  14. Retainer
  15. Grommet
  16. O-Ring
  17. Grommet

(verify printed p.138) — items 1-9’s exact numbering is reconstructed from a scattered list of the digits 1 through 9 (each appearing exactly once near this item group) combined with the item names appearing in this same reading order; confidence is reasonable but not certain. Items 10-17 are directly numbered in the source and are high-confidence.

Torque values called out on this page’s diagram (fastener assignment for each not confirmed — verify printed p.138):

  • 9.8-12 N·m (1.0-1.2 kgf·m; 87-106 in-lb)
  • 9 N·m (0.9 kgf·m; 80 in-lb)
  • 5 N·m (0.5 kgf·m; 44 in-lb)
  • 12 N·m (1.2 kgf·m; 106 in-lb)

Note: when installing injectors, coat grommets and O-rings with engine oil before installation — failure to do so can impede proper sealing.

Figure: Fuel Rail & Injector component removal diagram with torque callouts

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