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FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0]

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Special Service Tool (SST)

49 JP09 0A0   Injector remover

49 JP11 0A0   Injector seal installer set

Replacement part

Oil and chemical type

Warning

•  Always keep sparks and flames away from fuel. Fuel can be easily ignited which could cause serious injury or death, and damage to equipment.

•  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 a vehicle.

Caution

•  Be careful when handling the end area of the fuel injector. If the end area of the fuel injector is touched by hand or pressed against an object, it could cause a malfunction.

•  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.

1.  Perform the [Fuel Line Safety Procedure] referring to the [BEFORE SERVICE PRECAUTION]. (See BEFORE SERVICE PRECAUTION [SKYACTIV-X 2.0].)

2.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

4.  Remove the following parts. (See SIDE WALL REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

•  Left wall (rear)

•  Rear wall

5.  Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

6.  Remove the clip shown in the figure.

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7.  Remove the bolts and nuts and set the protector aside. (See SEAL COVER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

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8.  Remove the injection pipe (fuel injector side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

9.  Remove using the procedure shown in the figure.

10.  Install in the reverse order of removal.

11.  If the fuel injector is replaced, perform the fuel injection amount learning. (See FUEL INJECTION AMOUNT LEARNING [SKYACTIV-X 2.0].)

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1	Fuel injector connector
2	Fuel injector bracket
3	Fuel injector (See Fuel Injector Removal Note.) (See Fuel Injector Installation Note.)
4	O-ring (See O-Ring Installation Note.)
5	Gas seal (See Gas Seal Removal Note.) (See Gas Seal Installation Note.)

Fuel Injector Removal Note

1.  Install the SST (49 JP09 0A0) in the order shown in the figure.

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2.  Tighten No.5 shown in the figure and remove the fuel injector.

Gas Seal Removal Note

Note

•  When stretching the gas seal, do not damage the fuel injector with the tool.

1.  Stretch the gas seal as shown in the figure.

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2.  Remove the gas seal.

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Gas Seal Installation Note

Note

•  SST 49 JP11 001, 49 JP11 002, 49 JP11 003, 49 JP11 004, 49 JP11 005, and 49 JP11 006 are component parts for 49 JP11 0A0.

1.  Insert the SST (49 JP11 004) into the gas seal and move it to the end.

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2.  Install the SST (49 JP11 004) which the seal is installed to the end area of the fuel injector.

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3.  Press the gas seal to the fuel injector side using the SST 49 JP11 005 and 49 JP11 006.

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4.  Verify that the gas seals are installed to the correct positions as shown in the figure.

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•  If a gas seal is installed to an incorrect position, replace it with a new one.

5.  Lightly press the installed gas seals installed as shown in the figure, align them with the fuel injector grooves, and then smooth them evenly with fingers.

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Caution

•  When using the SSTs (49 JP11 002, 49 JP11 003), do not turn the SSTs.

6.  Slide the SST (49 JP11 002) to the end area of the fuel injector.

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7.  Put the fuel injector with the installed SST (49 JP11 002) on the work bench as shown in the figure and press in the fuel injector until it contacts the SST.

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8.  Maintain the SST for approx. 3 min.

9.  Verify that the gas seals are not damaged.

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•  If there is any damage, replace with a new gas seal.

10.  Change from the SSTs (49 JP11 004, 49 JP11 002) used in Steps 1 and 6 to the SSTs (49 JP11 001, 49 JP11 003) and install the second gas seal using the same procedure as in Steps 1 to 9.

O-Ring Installation Note

1.  Insert an O-ring from the end of the fuel injector as shown in the figure and install it to the correct position.

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Fuel Injector Installation Note

Replacing with a new fuel injector

1.  Verify that the numeral [2] is indicated on the connector area of the new fuel injector.

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•  If a numeral other than [2] is indicated on the connector area of the new fuel injector, replace it with a new fuel injector which indicates the numeral [2].

2.  As shown in the figure, temporarily install the fuel injectors to the fuel injector installation holes being careful of the direction in which the fuel injectors are pointed.

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3.  Press the top of the cap installed to the new fuel injector and press in the fuel injector until it is seated.

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4.  Remove the cap.

5.  Align the connection areas of the fuel injectors with the fuel injector bracket installation holes and assemble.

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6.  Install the bracket following procedure.

(1)  Install the bracket with its bent ends facing downward as shown in the figure.

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(2)  Temporarily tighten the bolts by approx. 3 threads.

(3)  Tighten the bolt.

Fuel injector is reused

Caution

•  When reusing a fuel injector, the thread area of the fuel injector could cut a finger.

Note

•  When reassembling a fuel injector, be careful that foreign matter does not get inside the fuel injector inlet.

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1.  As shown in the figure, temporarily install the fuel injectors to the fuel injector installation holes being careful of the direction in which the fuel injectors are pointed.

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2.  Align the connection areas of the fuel injectors with the fuel injector bracket installation holes and assemble.

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3.  Install the bracket following procedure.

(1)  Install the bracket with its bent ends facing downward as shown in the figure.

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(2)  Temporarily tighten the bolts by approx. 3 threads.

(3)  Tighten the bolt.