HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))]
HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))]
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Replacement Part
High pressure fuel pipe
Quantity: 1
Location of use: High pressure fuel pump
Seal rubber
Quantity: 1
Location of use: High pressure fuel pump
O-ring
Quantity: 1
Location of use: High pressure fuel pump
Gasket
Quantity: 1
Location of use: Rear housing
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Oil and Chemical Type
Engine oil
Type: Recommended oil
Silicone sealant
Type: TB1217D or equivalent
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 performing work on the fuel system, discharge static electricity by touching the vehicle body.
Caution
• Do not disassemble the high pressure fuel pump.
• Do not damage the sealing surface or the lock part of the fuel pipe.
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• Damage or deformation to the end of the high pressure line pipe may cause fuel leakage.
• Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.
• When removing the high pressure fuel pipe, the end of the high pressure fuel pipe may be damaged because the clearance between the high pressure fuel pump and the high pressure fuel pipe is small. Be very careful when handling the end of the high pressure fuel pipe so as not to damage it.
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• If the high pressure fuel pump is removed with the high pressure fuel pipe installed, the high pressure fuel pipe and fuel distributor may be damaged because of the excessive force caused by the spring force of the high pressure fuel pump. The high pressure fuel pipe and fuel distributor must be replaced if they are damaged. Always remove the high pressure fuel pipe before removing the high pressure fuel pump.
1. Remove the high pressure fuel pipe.
Rear Housing Removal Note
1. Disconnect the hose clips shown in the figure.
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2. Remove the bracket shown in the figure.
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3. Disconnect the exhaust CMP sensor connector.
4. Remove the bolts shown in the figure and set the bracket aside so that it does not interfere with the servicing.
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5. Remove the rear housing.
Rear Housing Installation Note
Note
• After applying silicone sealant (TB1217D or equivalent), install the rear housing within 10 min. and then tighten all bolts within 5 min.
1. Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.
2. Rotate the crankshaft approx. 30 degrees from TDC of cylinder No.1.
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3. Insert the high pressure fuel pump into the rear housing.
4. Press in the high pressure fuel pump until the O-ring cannot be seen.
5. Temporarily tighten the high pressure fuel pump installation bolt on one side until its head contacts the high pressure fuel pump.
6. Tighten the high pressure fuel pump installation bolt which is not tightened in Step 4.
7. Tighten the high pressure fuel pump installation bolt which was tightened in Step 4.
High Pressure Fuel Pipe Installation Note
Caution
• Damage or deformation to the end of the high pressure fuel pipe may cause fuel leakage. When installing the high pressure fuel pipe to the high pressure fuel pump, be very careful while handling the end of the high pressure fuel pipe.
• If parts are exposed to fuel, their function may be decreased or a fire may occur. Always wipe off any leaked fuel using a clean rag.
• Do not let foreign materials enter into the high pressure fuel pipe.
• Install a new high pressure fuel pipe because it cannot be reused.
1. Temporarily tighten the nuts on both ends.
2. Temporarily tighten the high pressure fuel pipe bracket installation bolt.
3. Tighten the nuts on both ends.
4. Tighten the high pressure fuel pipe bracket installation bolt.
Fuel Leakage Inspection After High Pressure Fuel Pump Installation
1. Verify that the high pressure fuel pump is assembled securely.
2. Verify that there is no fuel leakage around the high pressure fuel pump.
