SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2]

id0114f2805700

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”.

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.

•  To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing and installing the fuel injector.

•  If fuel does not pass through the fuel filter, foreign material may have penetrated in the supply pump, and this may cause a malfunction resulting in damage to the supply pump. Therefore, do not install the fuel hoses (main and return side) in reverse. When installing the fuel hose, always follow the Fuel Hose Installation Note in the Workshop Manual and perform the procedure. (See Fuel Hose Installation Note.)

Note

•  If the supply pump is replaced, always perform each adjustment procedure using the following steps.

STEP	ACTION	PAGE/CONDITION
1	Replace the supply pump.	–
2	Switch the ignition to on.	–
3	Perform supply pump data reset procedure.	(See SUPPLY PUMP DATA RESET [MZR-CD 2.2].)
4	Start the engine. Note •  Idling for 30 s or more	Verify that the MIL dose not illuminate.
5	Switch the ignition to off (Engine off).	–
6	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
7	Switch the ignition to off.	–
8	Wait for 20 s.	–
9	Start the engine.	–
10	Perform KOER self-test procedure.	Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2 PID) is 100 °C {212 °F} or more. (See KOEO/KOER SELF TEST [MZR-CD 2.2].)
11	Switch the ignition to off.	–

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

2.  Remove the engine cover. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

3.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Remove the air inlet hose No.1, air inlet hose No.2 and air inlet pipe as single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [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].)

am6zzw00005705

1	Fuel hose (See Fuel Hose Installation Note.)
2	Injection pipe (supply pump side)
3	Suction control valve connector
4	Supply pump (See Supply Pump Installation Note.)
5	Spacer

Supply Pump Installation Note

1.  Visually inspect the O-ring.

•  If there is any malfunction, replace the O-ring.

Fuel Hose Installation Note

1.  Install the fuel main hose and fuel return hose as shown in the figure.

L.H.D.

am6zzw00004266

R.H.D.

am6zzw00004267

2.  Fit the fuel pipe onto the respective fittings, and install clamps as shown.

am6zzw00004268