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INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0]

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Special service tool (SST)

49 JP02 003   Fuel pipe flare nut wrench

Replacement part

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

•  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.

•  Because the removed injection pipe cannot be reused, always install a new one.

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 following parts as a single unit. (See AIR CLEANER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

•  Air cleaner

•  Air hose

•  Fresh-air duct

6.  Remove the resonance chamber. (See AIR CLEANER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

7.  Remove the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

8.  Remove the battery tray and PCM as a single unit. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

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

10.  Disconnect the clips shown in the figure.

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

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12.  Remove the oil filler cap.

13.  Remove the oil filler pipe.

(1)  Detach the tabs using a flathead screwdriver.

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(2)  Pull out the oil filler pipe.

14.  Disconnect the connector shown in the figure and remove the bolts.

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15.  Disconnect the ignition coil No.4 connector.

16.  Remove ignition coil No.4.

17.  Remove the fuel injector connector.

18.  Set aside the EGR cooler with the water hose connected. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

19.  Disconnect the hoses shown in the figure.

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20.  Set aside the throttle body with the water hose connected. (See THROTTLE BODY REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

21.  Remove the water pipe bolt shown in the figure.

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22.  Remove the bracket shown in the figure. (See SUPERCHARGER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

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23.  Remove the bracket shown in the figure. (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

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24.  Remove the bracket shown in the figure. (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

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25.  Set aside the EGR pipe with the EGR sensor hose connected. (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

26.  Disconnect the quick release connector shown in the figure. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

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27.  Remove the bracket shown in the figure.

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28.  Remove the bracket shown in the figure.

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29.  Remove the injection pipe. (See Injection Pipe (High Pressure Fuel Pump Side) Removal Note.) (See Injection Pipe Installation Note.)

30.  Install in the reverse order of removal.

Injection pipe (fuel injector side)

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Injection pipe (high pressure fuel pump side)

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Injection Pipe (High Pressure Fuel Pump Side) Removal Note

1.  Remove the injection pipe (high pressure fuel pump side) using the SST.

Fuel distributor side

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High pressure fuel pump side

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Injection Pipe Installation Note

1.   Perform the following procedure.

If the fuel distributor has been removed:

1.   Temporarily tighten the fuel distributor.

If the fuel distributor has not been removed:

1.   Loosen the fuel distributor.

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2.  Temporarily tighten the injection pipes.

3.  Temporarily tighten the injection pipe (high pressure fuel pump side) brackets.

4.  Perform the following procedure.

If the high pressure fuel pump has been removed:

1.  Temporarily tighten the fuel pipe and fuel pipe bracket.

If the high pressure fuel pump has not been removed:

1.  Temporarily tighten the fuel pipe bracket.

5.  Tighten the fuel injection pipe connector in the order shown in the figure.

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(1)  Fuel distributor connectors (4 locations) of injection pipe (fuel injector side)

(2)  Fuel distributor connector of injection pipe (high pressure fuel pump side)

(3)  Fuel injector connectors (4 locations) of injection pipe (fuel injector side)

(4)  High pressure fuel pump connector of injection pipe (high pressure fuel pump side)

(5)  Brackets (2 locations) of injection pipe (high pressure fuel pump side)

6.  Perform the following procedure.

If the high pressure fuel pump has been removed:

1.  Tighten the fuel pipe and fuel pipe bracket.

If the high pressure fuel pump has not been removed:

1.  Tighten the fuel pipe bracket.

7.  Tighten the fuel distributor to the specified torque. (See FUEL DISTRIBUTOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)