SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

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  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.
  • The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the service record when removing and installing the fuel injection pipe. If removing it for the sixth time, be sure to replace it with a new one.
  • 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 | Turn the engine switch on. | –
3 | Perform supply pump data reset procedure. | Engine coolant temperature 60—100 °C {140—212 °F} (See SUPPLY PUMP DATA RESET [MZR-CD (RF Turbo)].)
4 | Start the engine. Note • Idling for 30 s or more. | Verify that the MIL does not illuminate.
5 | Turn the engine switch off. | –
6 | Turn the engine switch on (Engine off). | –
7 | Perform KOEO self-test procedure. | (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
8 | Turn the engine switch off. | –
9 | Wait for 20 s. | –
10 | Start the engine. | –
11 | Perform KOER self-test procedure. | Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2, EXHTEMP3 PID) is 100 °C {212 °F} or more. (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
12 | Turn the engine switch off. | –

1. Disconnect the negative battery cable.

2. Remove the under cover and splash shield.

3. Remove the dipstick pipe.

4. Remove the No.3 engine mount. (See TIMING BELT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

5. Remove the upper timing belt cover.

6. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD (RF Turbo)].)

7. Remove in the order indicated in the table.

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1 | Injection pipe
2 | Nozzle seal
3 | Fuel hose (See Fuel Hose Installation Note)
4 | Common rail (See Common Rail Installation Note)
5 | Supply pump (See Supply Pump Removal Note.) (See Supply Pump Installation Note.)

8. Install in the reverse order of removal.

9. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD (RF Turbo)].)

Supply Pump Removal Note

1. Verify that timing marks are correctly aligned.

  Caution
  • Do not fully tighten the anti-rotation bolt to prevent damage to the supply pump bracket and supply pump pulley.

2. Lock the supply pump pulley against rotation using the FIP repair kit (RFY1-13SM0).

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3. Remove the supply pump pulley lock nut.

4. Remove the supply pump lock nut.

5. Separate the supply pump pulley from the supply pump shaft using the SST.

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6. Remove the SST.

Supply Pump Installation Note

1. Lock the supply pump pulley against rotation using the FIP repair kit (RFY1-13SM0).

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2. Install the supply pump lock nut.

  Tightening torque

  18.6—25.5 N·m {1.9—2.6 kgf·m, 13.8—18.8 ft·lbf}

3. Install the supply pump pulley lock nut.

  Tightening torque

  58.8—68.6 N·m {6.0—6.9 kgf·m, 43.4—50.5 ft·lbf}

4. Remove the FIP repair kit.

5. Rotate the crankshaft clockwise 2—3 turns and align the timing marks.

6. Verify that timing marks are correctly aligned.

  • If not align all timing marks, align the timing marks. (See TIMING BELT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Common Rail Installation Note

1. Temporarily tighten the common rail.

2. Temporarily tighten the injection pipes.

3. Fully tighten the injector side injection pipes, then tighten the common rail side.

  Tightening torque

  40—50 N·m {4.1—5.0 kgf·m, 30—36 ft·lbf}

4. Fully tighten the supply pump side and common rail side injection pipes.

  Tightening torque

  40—50 N·m {4.1—5.0 kgf·m, 30—36 ft·lbf}

5. Fully tighten the common rail.

  Tightening torque

  18.6—25.5 N·m {1.9—2.6 kgf·m, 13.8—18.8 ft·lbf}

Fuel Hose Installation Note

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

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

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