SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

Oil and Chemical Type

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. Always tighten the injection pipe to the specified torque.

•  To prevent fuel leakage, when removing/installing the supply pump, always follow the procedure in the Workshop Manual and perform the procedure.

Note

•  If the supply pump is removed/installed or replaced, perform the “Operation After Removed/Installed or Replacing Supply Pump” procedure.

Operation After Removed/Installed or Replacing Supply Pump

1.  If the supply pump is removed/installed or replaced, perform the following procedure.

STEP	ACTION	PAGE/CONDITION
1	Perform supply pump data reset procedure.	(See SUPPLY PUMP DATA RESET [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	Maintain the idle status for 30 s with the following condition met. •  ECT: 60—100 °C {140—212 °F}	—
7	Perform KOER self-test procedure.	(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)

Supply Pump 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.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

6.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose

•  Air inlet pipe

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

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

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

10.  Remove the nuts and set the turbocharger air outlet pipe component aside. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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11.  Set the water pipe assy aside as shown in the figure.

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12.  Detach the hose clip shown in the figure.

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13.  Disconnect the vacuum hose shown in the figure.

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14.  Remove in the order shown in the figure.

15.  Install in the reverse order of removal.

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

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1	Clip installation nut
2	Fuel return pipe (fuel injector side) (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
3	Cover (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
4	Wiring harness clip
5	Fuel feed pipe
6	Injection pipe (supply pump side) (See Injection pipe (supply pump side) removal note.) (See Injection pipe (supply pump side) installation note.)
7	Clip
8	Bracket
9	Fuel return hose No.3 (See Fuel return hose No.3 installation note.)
10	Fuel return hose No.2 (See Fuel return hose No.2 installation note.)
11	Suction control valve connector
12	Supply pump (See Supply pump installation note.) (See Operation After Removed/Installed or Replacing Supply Pump.)
13	Connector No.1 (See Connector No.1 installation note.)
14	Connector No.2
15	Spacer

Injection pipe (supply pump side) removal note

1.  Remove the injection pipe (supply pump side) as shown in the figure. (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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(1)  Move the flared section.

(2)  Pull out the injection pipe (supply pump side).

2.  Remove the injection pipe (supply pump side).

Connector No.1 installation note

1.  Install the connector No.1 as shown in the figure so that the pipe does not cover the bolt.

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Supply pump installation note

Caution

•  To prevent silicone sealant (TB1217D or equivalent) from hardening, adhere the supply pump to the cylinder head within 10 min after applying silicone sealant (TB1217D or equivalent). Tighten the installation bolts completely soon after adhering.

1.  Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

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Fuel return hose No.2 installation note

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

Supply pump side

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Lower case side

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Fuel return hose No.3 installation note

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

Supply pump side

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Lower case side

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Injection pipe (supply pump side) installation note

1.  Install the injection pipe (supply pump side) as shown in the figure. (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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