COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2]

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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.

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

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

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

4.  Remove the dipstick. (See CYLINDER HEAD GASKET REPLACEMENT [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].)

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

Injection Pipe (Supply Pump Side) Removal Note

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

•  Fuel injector connector

•  Boost sensor 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 (supply pump side).