SUPPLY PUMP 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.

•  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

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

2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION[MZ-CD 1.6 (Y6)].)

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

4.  Remove the fuel metering valve. (See Fuel Metering Valve Removal/Installation Note.)

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

6.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

7.  Remove the splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

8.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZ-CD 1.6 (Y6)].)

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

10.  Remove the glow plug cord stay. (See GLOW PLUG REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

11.  Remove in the order indicated in the table.

12.  Install in the reverse order of removal.

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

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1	Timing belt (See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)].)
2	Supply pump pulley nut (See Supply Pump Pulley Nut Removal Note.) (See Supply Pump Pulley Nut Installation Note.)
3	Supply pump pulley (See Supply Pump Pulley Removal Note.)
4	Injection pipe
5	Connector
6	Supply pump bracket
7	Supply pump

Supply Pump Pulley Nut Removal Note

1.  Using the SSTs, hold the supply pump pulley nut 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 Pulley Nut Installation Note

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

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EURO5 Emission Level

Note

•  If the supply pump is replaced, complete the “HIGH PRESSURE FUEL SYSTEM LEARNED VALUES RESET”. (See HIGH PRESSURE FUEL SYSTEM LEARNED VALUES RESET [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

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

2.  Remove the fuel metering valve. (See FUEL METERING VALVE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3.  Remove the following parts:

(1)  Engine cover (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

(2)  Drive belt (See DRIVE BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

(3)  Coolant reserve tank with the hoses and pipes still connected (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4.  Set the cooler hose (LO) out of the way. (See REFRIGERANT LINE REMOVAL/INSTALLATION.)

5.  Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

6.  Remove and dispose of the injection pipe (supply pump side). (See COMMON RAIL REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

7.  The position shown in figure is protected with the tape.

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8.  Remove the nut using the SST as shown in the figure.

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9.  Remove the bolt as shown in the figure.

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10.  Remove the supply pump and supply pump bracket No.1 and supply pump pulley as single unit.

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11.  Install the SST as shown in the figure.

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12.  Remove the supply pump pulley.

13.  Remove the supply pump.

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14.  Remove the supply pump bracket No.2.

15.  Install in the reverse order of removal.

Fuel Metering Valve Removal/Installation Note

2.   Install in the reverse order of removal.

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