Common Rail Fuel Rail (Mazda CX-5KE)

Removal and installation the Common Rail fuel rail

Attention.

• Leaks in fuel lines in a pressurized system are dangerous. Fuel can ignite and cause equipment damage, serious injury, or even death. Fuel can also come into contact with human skin and eyes. To prevent this, it is essential to perform a pressure relief procedure in the fuel system.
• A person carrying a static charge can cause a fire or explosion, which could result in death or serious injury. Before working on the fuel system, you must discharge static electricity by touching the vehicle body.
• If fuel gets on engine parts, it may cause damage to those components or cause a fire. Be sure to wipe up any spilled fuel with a clean rag.
• Prevent foreign materials from entering the high-pressure fuel line. To do this, be sure to tighten the high-pressure fuel line connections to the specified tightening torque.

Note: If the Common Rail fuel rail is replaced, it is necessary to perform the procedure for teaching the amount of fuel injected by the injection system.

Removal the Common Rail Fuel Rail

1. Disconnect the negative battery terminal.

2. Perform the procedure for preparing for servicing the power supply system.

3. Remove the decorative engine cover.

4. Remove all high pressure fuel lines.

5. Disconnect the fuel rail pressure sensor connector.

Note: : replace the part with a new one after each removal.

6. Disconnect the fuel pressure limiting valve connector.



7. Disconnect the return fuel hose by removing the clamp or unscrewing the hollow bolt from the fuel rail.

8. Loosen the mounting nuts and remove the Common Rail fuel rail from the engine.

Installing a Common Rail Fuel Rail

1. Install the fuel rail on the engine and tighten the mounting nuts.



2. Tighten the connecting nuts of the new high-pressure fuel line on the fuel pump side.

3. Tighten the connecting nuts of the new high-pressure fuel lines on the injector side.

4. Fit the return fuel line.

5. Tighten the new clamp to a torque of 4.2-5.2 Nm.

6. Tighten the high-pressure fuel line bracket on the fuel pump side to a torque of 8-11 Nm.

7. Tighten the connecting nuts of all high-pressure fuel lines on the fuel rail side to a torque of 32-42 Nm.

8. Tighten the connecting nuts of all high-pressure fuel lines on the side of the high-pressure fuel pump and injectors to a torque of 32-42 Nm.

9. Tighten the Common Rail fuel rail mounting nuts to a torque of 20-26 Nm.

10. Tighten the hollow bolt of the fuel return line to a torque of 13-16 Nm.

Note: Install the fuel return hose as shown in the figure.

Checking the Common Rail Fuel Rail

Caution: It is extremely dangerous to remove the fuel pressure sensor and pressure limiting valve from the Common Rail fuel rail, as this may cause fuel leaks later. Do not remove the pressure sensor and pressure limiting valve from the Common Rail fuel rail.

Visually check for cracks, damage or rust on the Common Rail fuel rail. If any defects are found, replace the fuel rail with a new one.