COMMON RAIL REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)]

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.

• Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction 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.

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3. Disconnect the negative battery cable.

4. Remove the engine cover.

5. Disconnect the fuel injector connector.

6. Remove the EGR valve and pipe.

(See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

7. Remove in the order indicated in the table.

8. Install in the reverse order of removal.

9. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

High-pressure Fuel Pipe Installation Note

Note

• If it is not possible to correctly install the new high-pressure fuel pipe, it will be necessary to remove the remaining high-pressure fuel pipes and to loosen the common rail to allow correct alignment.

1. Install the fuel injector high-pressure fuel pipe.

2. Hand tighten the high-pressure fuel pipe unions.

Note

• Individual high-pressure fuel pipes must have both unions tightened to Step 1 and then Step 2 before continuing on to the next high-pressure fuel pipe.

3. Tighten the high-pressure fuel pipe unions in two steps.

(1) 10 N·m {102 kgf·cm, 88.5 in·lbf}

(2) 23 N·m {2.3 kgf·m, 17 ft·lbf}

Oil Filler Body Installation Note

Note

• Install the oil filler body and the intake manifold retaining bolts in the sequence shown.

1. Tighten the intake manifold and oil filler body installation bolts in the following steps.

(1) Temporarily tighten the bolts.

(2) Tighten the bolts in the order shown in the figure.

Tighten torque

8.9-12.1 N·m {90.8-123.3 kgf·cm, 78.8-107.0 in·lbf}