COMMON RAIL REMOVAL/INSTALLATION [MZ-CD 1.6]

id011420803900

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.

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].)

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

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

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

4.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6].)

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

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

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

8.  Remove the charge air cooler outlet hose and intake shutter valve and intake air pipe No.2 as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

9.  Remove the intake air pipe No.1. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

10.  Remove the fuel filter. (See FUEL FILTER REMOVAL/INSTALLATION [MZ-CD 1.6].)

11.  Remove the EGR cooler with bypass valve and EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6].)

12.  Remove the intake air pipe No.3. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

13.  Remove in the order indicated in the table.

14.  Install in the reverse order of removal.

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

am3zzw00012508

1	Connector
2	Injection pipe (fuel injector side)
3	Injection pipe (supply pump side)
4	Common rail