COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2]

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Warning

• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.

• A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

Caution

• Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags to soak up the fuel.

• To prevent the fuel injection pipe from clogging, be careful that foreign material has not entered the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the fuel injection pipe.

1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

3. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

4. Remove the air inlet hose and air inlet pipe as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

5. Remove the dipstick. (See CYLINDER HEAD GASKET REPLACEMENT [MZR-CD 2.2].)

6. Remove in the order indicated in the table.

7. Install in the reverse order of removal.

8. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

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1

Boost sensor connector

2

Vacuum hose

3

Boost sensor

4

Injection pipe (supply pump side)

5

Injection pipe (fuel injector side)

(See Injection Pipe (Fuel Injector Side) Removal Note.)

6

Fuel return hose

7

Common rail

Injection Pipe (Fuel Injector Side) Removal Note

1. Disconnect the following parts and Set the fuel injector wiring harness out of the way.

• Fuel injector connector

• Fuel pressure sensor connector

• EGR cooler bypass valve control solenoid valve connector

• Front harness-short cord connector

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2. Remove the injection pipe (fuel injector side).

1	Boost sensor connector
2	Vacuum hose
3	Boost sensor
4	Injection pipe (supply pump side)
5	Injection pipe (fuel injector side) (See Injection Pipe (Fuel Injector Side) Removal Note.)
6	Fuel return hose
7	Common rail