HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0]

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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

•  Do not disassemble the high pressure fuel pump.

•  Do not damage the sealing surface or the lock part of the fuel pipe.

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•  Damage or deformation to the end of the high pressure line pipe may cause fuel leakage.

•  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 1.5, SKYACTIV-G 2.0].)

2.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION.)

3.  Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

4.  Remove the following parts:

(1)  Wiper arm and blade (See WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

(2)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(3)  Air box complete (See AIR BOX COMPLETE REMOVAL/INSTALLATION.)

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

8.  Complete the “Fuel Leakage Inspection After High Pressure Fuel Pump Installation”. (See Fuel Leakage Inspection After High Pressure Fuel Pump Installation.)

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1	High pressure fuel pump connector
2	Exhaust CMP sensor connector
3	Harness clip
4	Protector
5	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)
6	Intake CMP sensor connector
7	High pressure fuel pipe (See High Pressure Fuel Pipe Removal Note.) (See High Pressure Fuel Pipe Installation Note.)
8	High pressure fuel pump (See High Pressure Fuel Pump Installation Note.)
9	O-ring
10	Tension collar
11	Seal rubber
12	Rear housing (See Rear Housing Removal Note.) (See Rear Housing Installation Note.)

High Pressure Fuel Pipe Removal Note

Caution

•  When removing the high pressure fuel pipe, the end of the high pressure fuel pipe may be damaged because the clearance between the high pressure fuel pump and the high pressure fuel pipe is small. Be very careful when handling the end of the high pressure fuel pipe so as not to damage it.

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•  If the high pressure fuel pump is removed with the high pressure fuel pipe installed, the high pressure fuel pipe and fuel distributor may be damaged because of the excessive force caused by the spring force of the high pressure fuel pump. The high pressure fuel pipe and fuel distributor must be replaced if they are damaged. Always remove the high pressure fuel pipe before removing the high pressure fuel pump.

•  I pay attention so that a dent and a vice are not put on the plating in the high pressure fuel pipe surface at the time of SST use.

Note

•  Depending on the vehicle's period of manufacture, it is either equipped or not equipped with a high pressure fuel pipe cover. If the cover is removed, it is not necessary to reinstall it because the part has no effect on the vehicle's functions and performance.

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1.  Remove the high pressure fuel pipe using the SST.

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Rear Housing Removal Note

1.  Remove the insulator.

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2.  Remove the exhaust CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

3.  Remove the rear housing.

Rear Housing Installation Note

Note

•  After applying silicone sealant, install the rear housing within 10 min. and then tighten all bolts within 5 min.

1.  Apply silicone sealant to the areas shown in the figure.

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2.  Install the rear housing.

3.  Tighten the rear housing installation bolts.

4.  Install the exhaust CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

5.  Install the insulator.

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High Pressure Fuel Pump Installation Note

1.  Rotate the timing mark clockwise approx. 30 degrees from the TDC (position shown in the figure) of cylinder No. 1.

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2.  Insert the high pressure fuel pump into the rear housing.

3.  Press in the high pressure fuel pump until the O-ring cannot be seen.

4.  Temporarily tighten the high pressure fuel pump installation bolt on one side until its head contacts the high pressure fuel pump.

5.  Tighten the high pressure fuel pump installation bolt which is not tightened in Step 4.

6.  Tighten the high pressure fuel pump installation bolt which was tightened in Step 4.

High Pressure Fuel Pipe Installation Note

Caution

•  Damage or deformation to the end of the high pressure fuel pipe may cause fuel leakage. When installing the high pressure fuel pipe to the high pressure fuel pump, be very careful while handling the end of the high pressure fuel pipe.

•  If parts are exposed to fuel, their function may be decreased or a fire may occur. Always wipe off any leaked fuel using a clean rag.

•  Do not let foreign materials enter into the high pressure fuel pipe.

•  Install a new high pressure fuel pipe because it cannot be reused.

1.  Temporarily tighten the nuts on both ends until they are seated to the nipple of the high pressure fuel pipe.

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2.  Temporarily tighten the high pressure fuel pipe bracket installation bolt.

Caution

•  Performing the procedure with the tightening nut angled at or away from the SST shaft could cause fuel leakage because the tightening nut cannot be tightened to the specified torque. Perform the procedure with the tightening nut and the SST shaft parallel to each other.

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•  I pay attention so that a dent and a vice are not put on the plating in the high pressure fuel pipe surface at the time of SST use.

3.  Tighten the nuts on both ends using the SST.

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4.  Tighten the high pressure fuel pipe bracket installation bolt.

Fuel Leakage Inspection After High Pressure Fuel Pump Installation

1.  Verify that the high pressure fuel pump is assembled securely.

2.  Verify that there is no fuel leakage around the high pressure fuel pump.