INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

Injection pipe (fuel injector side)
 
Quantity: 1
 
Location of use: Common rail
Injection pipe (supply pump side)
 
Quantity: 1
 
Location of use: Common rail

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 tighten the injection pipe to the specified torque.

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

5.  Remove in the order shown in the figure.

6.  Install in the reverse order of removal.

7.  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
Injection pipe (fuel injector side)
(See Injector Pipe Installation Note.)
2
Injection pipe (supply pump side)
(See Injection Pipe (Supply Pump Side) Removal Note.)
(See Injector Pipe Installation Note.)


Injection Pipe (Supply Pump Side) Removal Note

1.  Remove the battery and battery tray. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

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

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

6.  Remove the fuel feed pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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


Injector Pipe Installation Note

1.  Loosen the common rail.

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2.  Temporarily tighten the new injection pipe (supply pump side).

3.  Temporarily tighten the new injection pipes (fuel injector side).

4.  Temporarily install the fuel return pipe (supply pump side).

5.  Tighten the clip.

Tightening torque
4.0—6.0 N·m {41—61 kgf·cm, 36—53 in·lbf}

6.  Tighten the injection pipe (supply pump side) bracket.

Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

7.  Tighten the injection pipe (supply pump side) and the injection pipes (fuel injector side) on the common rail side.

Tightening torque
32—42 N·m {3.3—4.2 kgf·m, 24—30 ft·lbf}

8.  Tighten the injection pipe (supply pump side) and the injection pipes (fuel injector side) on the fuel injector side.

Tightening torque
32—42 N·m {3.3—4.2 kgf·m, 24—30 ft·lbf}

9.  Tighten the common rail.

Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

10.  Tighten the fuel feed pipe.

Tightening torque
Supply pump side: 18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}
Lower case side: 22—26 N·m {2.3—2.6 kgf·m, 17—19 ft·lbf}