Mitsubishi Pajero Pinin. Manual - part 92

GDI  – 

Injector

13A-117

INJECTOR

REMOVAL AND INSTALLATION

Caution
1.

Disconnect the negative battery cable prior to the service work.

2.

The injector driver may be hot immediately after each operation, and high voltage and current
flows between the injector driver and the injectors while the engine is running. Handle the
injector driver carefully.

Pre-removal and Post-installation Operation



Engine Cover Removal and Installation (Refer to
GROUP 11A – Camshaft and Camshaft Oil Seal.)



Prevention of Fuel Discharge <before removal only>



Fuel Leak Check <after installation only>



High-pressure Fuel Line Air Bleeding 
<after installation only> (P.13A-116.)

2

3

1

5

6

4

7

8

20

10

22  – 26 Nm

10  – 13 Nm

10  – 13 Nm

Apply engine oil to all
O-rings during installation.

21

18

9

13

16

17

11

12

19

14

15

8

10

9

20  – 25 Nm

Fuel pressure sensor removal steps

1. Fuel pressure sensor connector



A

 

E



2. Flange



E



3. Fuel pressure sensor



D



4. O-ring



D



5. Back-up ring

Injector removal steps



Intake manifold (Refer to GROUP 15.)

6. Injector connector



C



7. Fuel pipe



C



8. Back-up ring A



C



9. O-ring



C



10. Back-up ring B



B



11. Injector washer



B



12. Injector holder



B

 

B



13. Delivery pipe assembly



B



14. Insulator



B



15. Injector gasket



B

 

B



16. Injector assembly



A



17. Corrugated washer



A



18. Back-up ring A



A



19. O-ring



A



20. Back-up ring B
21. Injector

GDI  – 

Injector

13A-118

REMOVAL SERVICE POINT



A



FLANGE REMOVAL

If the fuel pressure sensor is reused, make mating marks
on the sensor and the flange before removal.

NOTE
The sealing performance and the installation rigidity of the
fuel pressure sensor can be secured by deforming the flange
when the sensor is installed. Therefore, the flange must be
reinstalled on the same side and phase as it is removed.
In addition, if the fuel pressure sensor is replaced, it should
be always replaced together with the flange.



B



DELIVERY PIPE ASSEMBLY/INJECTOR
ASSEMBLY REMOVAL

Remove the delivery pipe assembly with the injector assembly
still attached.

Caution
Be careful not to drop the injector assembly when
removing the delivery pipe assembly.

INSTALLATION SERVICE POINTS



A



BACK-UP RING B/O-RING/BACK-UP RING A
/CORRUGATED WASHER INSTALLATION

1.

Install the back-up rings and the O-ring as shown in the
illustration.

Caution
(1) Install the back-up ring B facing its cutaway

surface toward the opposite side of the O-ring
as shown in the illustration.

(2) Confirm the outer diameter of the back-up ring

A. Take care not to install the back-up ring for
the fuel pressure sensor by mistake. (Outer
diameter of the back-up ring A: 14.8 mm)

2.

Apply  petroleum jelly to the corrugated washer to prevent
it from falling off, and install it in the direction shown.

Caution
The corrugated washer should always be replaced
with a new part. If the corrugated washer is reused,
fuel or gas leak may occur.



B



FUEL INJECTOR ASSEMBLY/INJECTOR
GASKET/INSULATOR/DELIVERY PIPE
ASSEMBLY/INJECTOR HOLDER/INJECTOR
WASHER INSTALLATION

1.

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

Caution
Take care not to let any of the engine oil get inside
the delivery pipe assembly.

Flange

Fuel pressure
sensor

Mating mark

Cutaway
surface

Back-up ring A
(either side)

O-ring

Back-up 
ring B

A

A

Section A –  A

Corrugated
washer

GDI  – 

Injector

GDI  – 

Injector

13A-119

2.

Insert the injector assembly into the mounting hole on the
delivery pipe squarely. Then check that the fuel injector
turns smoothly.

3.

If the injector does not turn smoothly, the cause may be that
the O-ring is getting caught. Remove the fuel injector, check
the O-ring for damage and re-connect the injector to the
delivery pipe assembly and then re-check.

4.

Align the injector assembly mating mark with the delivery
pipe mating mark.

5.

Install the injector gasket and the insulator to the cylinder
head.

6.

Assemble the delivery pipe and injector assembly to the
cylinder head, then finger-tighten the mounting bolts.

7.

Assemble the injector holder and the injector washer, then
tighten the mounting bolts to the specified torque.

Tightening torque: 20 – 25 Nm

8.

Tighten the delivery pipe and injector assembly mounting
bolts to the specified torque in the order shown.

Tightening torque: 10 – 13 Nm



C



BACK-UP RING B/O-RING/BACK-UP RING A/FUEL
PIPE INSTALLATION

1.

Install the back-up rings and the O-ring as shown in the
illustration.
Caution
(1) Install the back-up ring B facing its cutaway

surface toward the opposite side of the O-ring
as shown in the illustration.

(2) Confirm the outer diameter of the back-up ring

A. Take care not to install the back-up ring for
the fuel pressure sensor by mistake. (Outer
diameter of the back-up ring A: 14.8 mm)

2.

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

Caution
Take care not to let any of the engine oil get inside
the fuel pump (high-pressure) or the delivery pipe
assembly.

3.

Install the fuel pipe into the fuel pump (high pressure) and
the delivery pipe ports squarely. Insert the pipe securely,
being careful not to twisting it, and then tighten the mounting
bolts to the specified torque.

Tightening torque: 10 – 13 Nm



D



BACK-UP RING/O-RING INSTALLATION

Assemble the back-up ring and the O-ring as shown.

Caution
Be careful not to confuse this back-up ring with back-up
ring A for the injector or the fuel pipe. (Back-up ring outer
diameter: 15.1 mm)

Mating
mark

1

3

4

2

A

A

Cutaway
surface

Back-up ring A
(either side)

O-ring

Back-up 
ring B

Section A –  A

Back-up ring 
(either side)

O-ring

A

A

Section A –  A

GDI  – 

Injector

13A-120



E



FUEL PRESSURE SENSOR/FLANGE
INSTALLATION

1.

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

Caution
Be careful not to allow the engine oil to enter the
delivery pipe.

2.

Make the part number on the fuel pressure sensor face
as shown. 
If the fuel pressure sensor is reused, align the mating
marks to install it to the delivery pipe.

Caution
If the fuel pressure sensor is replaced, always replace
it together with the flange.

Fuel pressure sensor

Parts number