Common Rail Removal/Installation: Notes

WARNING: This page is about a different variant/trim than selected.

Replacement Part

Washer
Quantity: 2
Location of use: Common rail

Fuel return hose No. 4
Quantity: 1
Location of use: Common rail

WARNING:

Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the "FUEL LINE SAFETY PROCEDURE " to prevent the fuel from spraying.
- Fuel may cause irritation if it comes in contact with skin and eyes.
- If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
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:

If parts are exposed to the fuel, their function may be decreased or a fire may occur. Spread a rag to absorb any leaked fuel.
Do not let foreign matter get into the injection pipe to prevent clogging. In addition, always tighten the injection pipe to the specified torque.

NOTE:

If the common rail is replaced, perform the "Fuel Injection Amount Learning".

Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
Perform the "Fuel Line Safety Procedure" referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION .)
Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION .)
Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
- Air hose
- Air inlet pipe
Disconnect the blow-by heater connector.
Set the turbocharger air inlet hose aside.
Disconnect the wiring harness clip shown in the figure.

Courtesy of MAZDA MOTORS CORP.
Disconnect the CMP sensor connector. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION .)
Remove the fuel return pipe (fuel injector side) and cover. (See FUEL INJECTOR REMOVAL/INSTALLATION .)
Remove the following parts. (See SUPPLY PUMP REMOVAL/INSTALLATION .)
- Fuel feed pipe
- Injection pipe (supply pump side)
- Clip
- Bracket
Remove in the order shown in the figure.
Install in the reverse order of removal.

Perform the "Fuel Hose Installation Procedure" and "Fuel Line Air Bleeding" referring to the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION .)

Fig 1: Removing/Installing Common Rail Components With Torque Specification

Courtesy of MAZDA MOTORS CORP.

COMPONENT DESCRIPTION

1	Fuel pressure relief valve connector
2	Fuel return hose No. 4 (See Fuel Return Hose No. 4 Installation Note .)
3	Common rail (See Common Rail Installation Note .)