LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

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.

•  If fuel does not pass through the fuel filter, it could cause a fuel system malfunction. Therefore, do not install the fuel hoses (main and return side) in reverse. When installing the fuel hose, always refer to the “AFTER SERVICE PRECAUTION” and perform the “Fuel Hose Installation Procedure”.

Fuel Injector (2pin type)

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

2.  Perform the “Fuel Line Safety Procedure” referring to the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Disconnect the fuel feed pipe (lower case side). (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the fuel return pipe (fuel injector side) and cover. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Remove in the order shown in the figure.

7.  Install in the reverse order of removal.

8.  Perform the Fuel Hose Installation and Fuel Line Air Bleeding referring to the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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1	Fuel main hose (See Fuel main hose and fuel return hose No.1 installation note (Fuel injector (2pin type)).)
2	Fuel return hose No.1 (See Fuel main hose and fuel return hose No.1 installation note (Fuel injector (2pin type)).)
3	Fuel return hose No.2 (See Fuel return hose No.2 installation note (Fuel injector (2pin type)).)
4	Fuel return hose No.3 (See Fuel return hose No.3 installation note (Fuel injector (2pin type)).)
5	Fuel return hose No.4 (See Fuel return hose No.4 installation note (Fuel injector (2pin type) Lower case side)).) (See Fuel return hose No.4 installation note (Fuel injector (2pin type) Common rail side).)
6	Plug (See Plug installation note (Fuel injector (2pin type)).)
7	Lower case

Plug installation note (Fuel injector (2pin type))

1.  Install plug as shown in the figure.

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Fuel return hose No.4 installation note (Fuel injector (2pin type) Lower case side))

1.  Install the fuel return hose No.4 as shown in the figure.

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Fuel return hose No.4 installation note (Fuel injector (2pin type) Common rail side)

1.  Install the fuel return hose No.4 as shown in the figure.

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Fuel return hose No.3 installation note (Fuel injector (2pin type))

1.  Install fuel return hose No.3 as shown in the figure.

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Fuel return hose No.2 installation note (Fuel injector (2pin type))

1.  Install fuel return hose No.2 as shown in the figure.

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Fuel main hose and fuel return hose No.1 installation note (Fuel injector (2pin type))

1.  Install the fuel main hose and fuel return hose No.1 as shown in the figure.

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Fuel Injector (6pin type)

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

2.  Perform the “Fuel Line Safety Procedure” referring to the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Disconnect the blow-by heater connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

7.  Disconnect the breather hose from the cylinder head cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

8.  Remove the turbocharger air inlet pipe and breather hose as single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Disconnect the fuel feed pipe (lower case side). (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Remove the fuel return pipe (fuel injector side) and cover. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Remove in the order shown in the figure.

12.  Install in the reverse order of removal.

13.  Perform the Fuel Hose Installation and Fuel Line Air Bleeding referring to the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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1	Fuel main hose (See Fuel main hose and fuel return hose No.1 installation note (Fuel injector (6pin type)).)
2	Fuel return hose No.1 (See Fuel main hose and fuel return hose No.1 installation note (Fuel injector (6pin type)).)
3	Fuel return hose No.2 (See Fuel return hose No.2 installation note (Fuel injector (6pin type)).)
4	Fuel return hose No.3 (See Fuel return hose No.3 installation note (Fuel injector (6pin type)).)
5	Fuel return hose No.4 (See Fuel return hose No.4 installation note (Fuel injector (6pin type) Lower case side).) (See Fuel return hose No.4 installation note (Fuel injector (6pin type) Common rail side).)
6	Plug (See Plug installation note (Fuel injector (6pin type)).)
7	Lower case

Plug installation note (Fuel injector (6pin type))

1.  Install plug as shown in the figure.

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Fuel return hose No.4 installation note (Fuel injector (6pin type) Lower case side)

1.  Install the fuel return hose No.4 as shown in the figure.

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Fuel return hose No.4 installation note (Fuel injector (6pin type) Common rail side)

1.  Install the fuel return hose No.4 as shown in the figure.

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Fuel return hose No.3 installation note (Fuel injector (6pin type))

1.  Install fuel return hose No.3 as shown in the figure.

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Fuel return hose No.2 installation note (Fuel injector (6pin type))

1.  Install fuel return hose No.2 as shown in the figure.

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Fuel main hose and fuel return hose No.1 installation note (Fuel injector (6pin type))

1.  Install the fuel main hose and fuel return hose No.1 as shown in the figure.

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