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LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 1.8]

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Replacement Part

Warning

•  Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. If fuel comes into contact with the skin and eyes it will cause irritation. To prevent this, always perform the “Fuel Line Safety Procedure” referring to the “BEFORE REPAIR PROCEDURE”.

•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before servicing the fuel system, make sure to discharge static electricity by touching a vehicle.

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.

•  If fuel does not pass through the fuel filter, it could cause a fuel system malfunction. Therefore, do not install the fuel hoses (main and return side) in reverse. When installing the fuel hose, always refer to the “AFTER SERVICE PRECAUTION” and perform the “Fuel Hose Installation Procedure”.

Note

•  The fuel temperature sensor cannot be removed as a single unit. When replacing the fuel temperature sensor, replace it together with the lower case as a single unit.

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

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

3.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.8].)

4.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

5.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

•  Air hose

•  Air inlet pipe

6.  Disconnect the CMP sensor connector. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

7.  Disconnect the fuel injector connector. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

8.  Disconnect the wiring harness clips shown in the figure.

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9.  Disconnect the exhaust gas temperature sensor No.1 connector. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

10.  Disconnect the exhaust gas temperature sensor No.1 connector clip. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

11.  Disconnect the vacuum hose shown in the figure. (See TURBOCHARGER SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

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12.  Disconnect the vacuum hose connected to the cylinder head cover.

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13.  Remove the bolts shown in the figure.

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14.  Remove the vacuum pipe installation bolt and set the vacuum pipe aside so that it does not interfere with the servicing.

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15.  Remove the fuel return pipe. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

16.  Remove the fuel injector insulator. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

17.  Remove the vacuum hose shown in the figure. (See VACUUM LINE INSPECTION [SKYACTIV-D 1.8].)

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18.  Disconnect the wiring harness clip shown in the figure.

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19.  Remove the fuel feed pipe. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

20.  Remove in the order shown in the figure.

21.  Install in the reverse order of removal.

22.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)

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1	Blind cap (See Blind Cap Installation Note.)
2	Fuel main hose No.1 (See Fuel Main Hose No.1 Installation Note.)
3	Fuel return hose No.1 (See Fuel Return Hose No.1 Installation Note.)
4	Fuel return hose No.2 (See Fuel Return Hose No.2 Installation Note.)
5	Fuel main hose No.2 (See Fuel Main Hose No.2 Installation Note.)
6	Fuel return hose No.3 (See Fuel Return Hose No.3 Installation Note.)
7	Lower case

Fuel Return Hose No.3 Installation Note

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

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Fuel Main Hose No.2 Installation Note

1.  Install fuel main hose No.2 as 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.

Lower case side

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Common rail side

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Fuel Return Hose No.1 Installation Note

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

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Fuel Main Hose No.1 Installation Note

1.  Install fuel main hose No.1 as shown in the figure.

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Blind Cap Installation Note

1.  Install blind cap as shown in the figure.

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