FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.5T]

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Replacement Part

Warning

•  Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to “BEFORE SERVICE PRECAUTION”.

•  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

•  Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

Caution

•  Because the fuel surface is higher than the fuel pump unit installation surface, if the set plate is removed, it may result in fuel leakage. If the fuel gauge level indicates 3/4 or more, refer to the fuel draining procedure and drain 20 liters of fuel.

2.  Using the following procedure:

Fuel gauge indicates 3/4 or more

1.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 2.5T].)

Fuel gauge indicates less than 3/4

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

3.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

4.  Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

5.  Disassemble in the order indicated in the table.

6.  Assemble in the reverse order of disassembly.

7.  Install in the reverse order of removal.

8.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

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1	Fuel gauge sender unit
2	Fuel filter (low-pressure)
3	Relief valve (See Relief Valve Installation Note.)
4	Check valve (See Check Valve Installation Note.)
5	Fuel pump
6	Fuel filter (high-pressure)

Check Valve Installation Note

Caution

•  When installing the check valve and the relief valve, verify the identification numbers and install them to the correct positions. Otherwise, the engine may stall.

1.  Verify that the identification number is for the check valve.

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2.  Install the check valve.

Relief Valve Installation Note

Caution

•  When installing the check valve and the relief valve, verify the identification numbers and install them to the correct positions. Otherwise, the engine may stall.

1.  Verify that the identification number is for the relief valve.

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2.  Install the relief valve.