FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Special Service Tool (SST)

49 0000 203   Injector bore cleaning kit

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.

•  Do not let foreign matter get into the injection pipe to prevent clogging. In addition, always install the injection pipe to the specified tightening torque.

•  If a hand or tool touches a fuel injector terminal or fuel injector connector terminal, the fuel injector might be damaged. To prevent damage to a fuel injector, do not touch the terminals.

•  If high-voltage generating parts or components and electronic devices come near a fuel injector, the fuel injector could be damaged. To prevent damage to a fuel injector, always keep high-voltage generating parts or components and electronic devices away from it.

Note

•  If the fuel injector is removed/installed or replaced, perform the “Operation After Removed/Installed or Replacing Fuel Injector” procedure.

Operation After Removed/Installed or Replacing Fuel Injector

1.  If the fuel injector is removed/installed or replaced, perform the following procedure.

STEP	ACTION	PAGE/CONDITION
1	Clear the DTCs.	(See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [PCM (SKYACTIV-D 2.2)].)
2	Switch the ignition off.	—
3	Wait for 30 s.	—
4	Switch the ignition ON (engine off).	—
5	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
6	Perform KOER self-test procedure.	(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
7	Perform fuel injector injection amount correction.	(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 2.2].)
8	Clear the DTCs.	(See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [PCM (SKYACTIV-D 2.2)].)

Fuel injector Removal/Installation

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 CMP sensor connector.

5.  Remove in the order shown in the figure.

6.  Install in the reverse order of removal.

7.  Refer to the “AFTER SERVICE PRECAUTION” and perform the fuel hose installation procedure and fuel line air bleeding. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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1	Fuel injector connector (See Fuel injector connector removal note.) (See Fuel injector connector installation note.)
2	Fuel return pipe (fuel injector side)
3	Cover
4	Injection pipe (fuel injector side) (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
5	Fuel injector bracket
6	Fuel injector (See Fuel injector removal note.) (See Fuel injector installation note.) (See Operation After Removed/Installed or Replacing Fuel Injector.)

Fuel injector connector removal note

Caution

•  If a hand or tool touches the fuel injector terminal, the fuel injector might be damaged. To prevent this, do not touch the terminal.

1.  Disconnect the fuel injector connector using the following procedure.

(1)  Move the lever.

(2)  Disconnect the connector.

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Fuel injector removal note

Caution

•  Do not apply excessive force to the bar to prevent damaging the cylinder head cover which the socket is set to.

1.  If it is difficult to remove the fuel injector, use a bar and socket set up as shown in the figure as leverage to lift the fuel injector bracket and then remove the fuel injector.

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2.  If the washers remain on the cylinder head, remove them using the following procedure.

(1)  Remove the washers remaining on the cylinder head using an injector washer remover.

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Fuel injector installation note

Note

•  Clean the injector hole and the bore using the following procedure and the SSTs (49 0000 203) shown in the figure.

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1	Round wire brush
2	Fleece brush
3	Wire brush
4	Blanking plug
5	Extension bar
6	Flexible shaft
7	Holder

1.  Install the blanking plug to the end of the extension bar.

2.  Insert the blanking plug into the injector hole, rotate the extension bar counterclockwise, and then block the injector hole using the blanking plug.

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3.  Install the round wire brush to the end of the flexible shaft.

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Caution

•  Install the holder and clean the bore to prevent damage to the bore.

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4.  Connect the flexible shaft installed to the round wire brush to the drill, and clean the bore.

5.  Clean the carbon that was cut off using an air gun.

6.  Cut (reference: diameter approx. 23 mm) the fleece brush so that it reaches the bottom surface, and install it to the flexible shaft.

Caution

•  Clean the bottom surface while verifying the cleaning surface condition. If the bottom surface is cleaned excessively, it could be damaged.

7.  Connect the flexible shaft installed to the fleece brush to the drill, and clean the bottom surface.

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8.  Clean the carbon that was cut off using an air gun.

9.  Insert the extension bar and remove the blanking plug.

10.  Clean the injector hole using a wire brush.

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11.  Temporarily install the fuel injector and the fuel injector bracket.

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12.  Loosen the common rail.

13.  Temporarily tighten the new injection pipe (fuel injector side).

14.  Tighten the new fuel injector bracket installation nuts using the following procedure.

Caution

•  If the fuel injector bracket installation nuts are tightened incorrectly, it could damage the fuel injector bracket and cause gas leakage due to incorrect installation. To prevent this, tighten the fuel injector bracket installation nuts using the following procedure.

Note

•  There is a scribe line engraved on the fuel injector bracket installation nut for tightening it to the specified angle. (The angles between the white paint mark and scribe line A, and between the yellow paint mark and scribe line B are both 230 degrees as shown in the figure)

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•  Tighten only the fuel injector bracket installation nuts on the engine rear side to the specified angle.

(1)  Temporarily tighten the nut on the engine front side (until nut is seated).

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(2)  Completely tighten the nut on the engine front side.

Tightening torque

2.0 N·m {20 kgf·cm, 18 in·lbf}

(3)  Loosen the nut on the engine front side 90 degrees.

(4)  Temporarily tighten the nut on the engine rear side (until nut is seated).

(5)  Completely tighten the nut on the engine rear side.

Tightening torque

2.0 N·m {20 kgf·cm, 18 in·lbf}

(6)  Draw a line on the fuel injector bracket at a right angle to the center of the scribe line (either A or B) on the surface of the nut on the rear side of the engine.

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Note

•  The drawn line on the fuel injector bracket is the standard angle to which the nut is tightened.

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(7)  Tighten the nut until the paint mark (same color step (6) or (7)) on the nut upper surface on the engine rear side comes to the position of the drawn line on the fuel injector bracket.

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Note

•  After tightening the nut following the procedure, the bolt projections differ as shown in the figure because the fuel injector bracket leans a little. This is the correct condition and retightening is not required.

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15.  Tighten the injection pipes (fuel injector side) on the common rail side.

16.  Tighten the injection pipes (fuel injector side) on the fuel injector side.

17.  Tighten the common rail.

18.  Install the cover.

19.  Tighten the fuel return pipe (fuel injector side) in the order shown in the figure.

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Fuel injector connector installation note

Caution

•  If a hand or tool touches the fuel injector terminal, the fuel injector might be damaged. To prevent this, do not touch the terminal.

1.  Connect the fuel injector connector using the following procedure.

(1)  Connect the connector.

(2)  Move the lever.

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