SUPPLY PUMP REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo]

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Warning

•  Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.

•  This procedure involves fuel handing. Be prepared for fuel spillage at all times and always observe fuel handing precautions. Failure to follow these instructions may result in personal injury.

•  Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction may result in personal injury.

•  Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury.

Caution

•  Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.

•  Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new injectors when required.

•  Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components.

Note

•  If the supply pump is replaced, complete the “SUPPLY PUMP ADAPTIVE VALUE RESET” (See SUPPLY PUMP ADAPTIVE VALUE RESET [MZ-CD 1.4 DI Turbo].)

1.  Follow “BEFORE SERVICE PRECAUTION” before perfoming any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.4 DI Turbo].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

3.  Remove the engine cover.

4.  Remove the cylinder head cover. (See CAMSHAFT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

5.  Remove the EGR valve and EGR cooler. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

6.  Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZ-CD 1.4 DI Turbo].)

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1	Injection pipe
2	Quick release connector (fuel main hose)
3	Quick release connector (fuel return hose)
4	Connector
5	Bracket
6	Supply pump pulley nut (See Supply Pump Pulley Nut Removal Note.) (See Supply Pump Pulley Nut Installation Note.)
7	Supply pump pulley (See Supply Pump Pulley Removal Note.)
8	Supply pump (See Supply Pump Removal Note.)

Supply Pump Pulley Nut Removal Note

1.  Using the SST, hold the supply pump pulley and remove the retaining nut.

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Supply Pump Pulley Removal Note

1.  Using the SST, remove the supply pump pulley.

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Supply Pump Removal Note

1.  Support the supply pump while removing the supply pump retaining bolts.

Supply Pump Pulley Nut Installation Note

1.  Using the SST, tighten the supply pump pulley retaining nut.

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