FUEL INJECTOR REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)]

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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 handling. Be prepared for fuel spillage at all times and always observe fuel handling 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. 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 fuel 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.

EURO4 Emission Level

Note

• If new fuel injectors are being installed, use the M-MDS and program the new fuel injector calibration codes into the PCM. (See FUEL INJECTOR CALIBRATION CODE PROGRAM [MZ-CD 1.6 (Y6) (EURO4 emission level)].)

1. Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION[MZ-CD 1.6 (Y6)].)

3. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)].)

4. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

5. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

6. Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

7. Remove the EGR pipe. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

8. Remove in the order indicated in the table.

9. Install in the reverse order of removal.

10. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

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1

Fuel injector connector

2

Fuel return hose

3

Injection pipe

4

Fuel injector

(See Fuel injector removal note.)

(See Fuel injector installation note.)

Fuel injector removal note

Caution

• The fuel injector calibration codes must be accurately recorded from the fuel injectors.

Note

• The example shown is not a valid calibration code and is to indicate the location the code only.

1. Make a note of the fuel injector calibration codes and their cylinder locations.

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2. Make a note of the position of the fuel injector threaded union before removal.

Fuel injector installation note

Caution

• Do not use excessive force to press the new fuel injection seal into the lower cylinder head cover using the SST. Failure to follow this instruction may result in damage to the fuel injector seal.

1. Press the new fuel injector seal into the lower cylinder head cover using the SST.

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2. Make sure the fuel injector bracket and clip is correctly installed.

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3. Remove the blanking plug from the fuel injector nozzle.

Note

• If original fuel injectors are to be installed, they must be matched to the cylinders they were removed from.

4. Install the fuel injector so that the threaded union is in the same position as when removed.

5. Install the fuel injector retaining bracket nuts hand tight.

6. Record the fuel injector calibration codes and the respective cylinder locations of all new fuel injectors.

EURO5 Emission Level

Note

• If the fuel injector is replaced, complete the “FUEL INJECTOR CORRECTION FACTORS” and “FUEL INJECTOR LEARNED VALUES RESET”. (See FUEL INJECTOR CORRECTION FACTORS [MZ-CD 1.6 (Y6) (EURO5 emission level)].) (See FUEL INJECTOR LEARNED VALUES RESET [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION[MZ-CD 1.6 (Y6)].)

3. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

4. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

5. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

6. Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

7. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

8. Remove the charge air cooler outlet hose and intake shutter valve and intake air pipe No.3 as single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

9. Remove the charge air cooler inlet hose and intake air pipe No.1 as single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

10. Remove the rubber protector.

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