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FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8]

FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8]

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Special Service Tool (SST)

49 0000 203
 
Injector bore cleaning kit

Replacement Part

Clip
 
Quantity: 5
 
Location of use: Fuel return pipe (fuel injector side)
Washer
 
Quantity: 4
 
Location of use: Fuel injector

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.
•  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.
•  If a hand or tool touches a fuel injector terminal or fuel injector connector terminal, the fuel injector might be damaged. To prevent damage to a fuel injector, do not touch the terminals.
•  If high-voltage generating parts or components and electronic devices come near a fuel injector, the fuel injector could be damaged. To prevent damage to a fuel injector, always keep high-voltage generating parts or components and electronic devices away from it.
Note
•  If the fuel injector is replaced or removed/installed, perform the “Operation After Replacing or Removal/Installation Fuel Injector” procedure.

Operation After Replacing or Removal/Installation Fuel Injector

1.  If the fuel injector is replaced or removed/installed, perform the following procedure.

STEP

ACTION

PAGE/CONDITION
1
Clear the DTCs.
(See CLEARING DTC.)
2
Switch the ignition off.
—
3
Wait for 30 s or more.
—
4
Switch the ignition ON (engine off).
—
5
Perform KOEO self-test procedure.
(See DTC INSPECTION.)
6
Perform KOER self-test procedure.
(See DTC INSPECTION.)
7
Perform fuel injector injection amount correction.
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 1.8].)
8
Clear the DTCs.
(See CLEARING DTC.)


Fuel injector Removal/Installation

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

5.  Disconnect the fuel injector connector. (See Fuel injector connector removal note.) (See Fuel injector connector installation note.)

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

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

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

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

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

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11.  Remove the bolts shown in the figure.

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12.  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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13.  Remove the injection pipe (fuel injector side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

14.  Remove in the order shown in the figure.

15.  Install in the reverse order of removal.

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

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1
Fuel return pipe
2
Fuel injector insulator
3
Fuel injector bracket
4
Fuel injector
(See Operation After Replacing or Removal/Installation Fuel Injector.)
(See Fuel injector installation note.)


Fuel injector connector removal note

Caution
•  If a hand or tool touches the fuel injector terminal, the fuel injector might be damaged. To prevent this, do not touch the terminal.

1.  Disconnect the fuel injector connector using the following procedure.

(1)  Move the lever.
(2)  Disconnect the connector.

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Fuel injector installation note

1.  Remove the injection pipe (supply pump side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

2.  Loosen the common rail.

3.  Tighten the bolts shown in the figure to the specified torque.

Caution
•  The bolts shown in the figure may loosen when removing the fuel injector bracket because the nuts assembled to the bolts are removed. Tighten the bolts shown in the figure to the specified torque before installing the fuel injector bracket.
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Note
•  Clean the injector hole and the bore using the following procedure and the SSTs (49 0000 203) shown in the figure.
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1
Round wire brush
2
Fleece brush
3
Wire brush
4
Blanking plug
5
Extension bar
6
Flexible shaft
7
Holder

4.  Install the blanking plug to the end of the extension bar.

5.  Insert the blanking plug into the injector hole, rotate the extension bar counterclockwise, and then block the injector hole using the blanking plug.

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6.  Install the round wire brush to the end of the flexible shaft.

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Caution
•  Install the holder and clean the bore to prevent damage to the bore.
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7.  Connect the flexible shaft installed to the round wire brush to the drill, and clean the bore.

8.  Clean the carbon that was cut off using an air gun.

9.  Cut (reference: diameter approx. 23 mm) the fleece brush so that it reaches the bottom surface, and install it to the flexible shaft.

Caution
•  Clean the bottom surface while verifying the cleaning surface condition. If the bottom surface is cleaned excessively, it could be damaged.

10.  Connect the flexible shaft installed to the fleece brush to the drill, and clean the bottom surface.

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11.  Clean the carbon that was cut off using an air gun.

12.  Insert the extension bar and remove the blanking plug.

13.  Clean the injector hole using a wire brush.

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14.  Temporarily install the fuel injector and the fuel injector bracket.

15.  Temporarily tighten the common rail installation nut.

16.  Temporarily tighten both ends of the new injection pipe (fuel injector side) and injection pipe (supply pump side) in the order shown in the figure.

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17.  Tighten the fuel injector bracket installation nuts in two steps.

18.  Temporarily tighten the fuel feed pipe. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

19.  Tighten the clip. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

20.  Tighten the injection pipe (supply pump side) bracket installation bolts. (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

21.  Tighten both ends of the injection pipe (fuel injector side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

22.  Tighten both ends of the injection pipe (supply pump side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

23.  Tighten the common rail. (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

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

25.  Install the fuel injector insulator.

26.  Tighten the fuel return pipe.


Fuel injector connector installation note

Caution
•  If a hand or tool touches the fuel injector terminal, the fuel injector might be damaged. To prevent this, do not touch the terminal.

1.  Connect the fuel injector connector using the following procedure.

(1)  Connect the connector.
(2)  Move the lever.

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