LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 1.5]

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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 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 cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 1.5].)

2. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

3. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.5].)

4. Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

5. Remove the vacuum pipe bolt shown in the figure.

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6. Remove the vacuum hose shown in the figure.

L.H.D.

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R.H.D.

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7. Remove in the order shown in the figure.

8. Install in the reverse order of removal.

9. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.5].)

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Fuel Return Hose No.4 Removal Note

1. Remove the lower case bolts and turn the lower case upside down.

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2. Disconnect fuel return hose No.4 from the lower case.

Lower Case Removal Note

1. Remove the following parts as a single unit:

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• Lower case

• Fuel return hose No.2

• Fuel return hose No.3

2. Remove fuel return hose No.2 and fuel return hose No.3 from the lower case.

Lower Case Installation Note

1. Install the following parts as a single unit:

• Fuel return hose No.3

• Fuel return hose No.2

• Lower case

Fuel Return Hose No.4 Installation Note

1. Install fuel return hose No.4 as shown in the figure.

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Fuel Return Hose No.3 Installation Note

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

Lower case side

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Supply pump side

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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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1	Fuel temperature sensor connector
2	Blind cap (See Blind Cap Installation Note.)
3	Fuel main hose No.1 (See Fuel Main Hose No.1 Installation Note.)
4	Fuel return hose No.1 (See Fuel Return Hose No.1 Installation Note.)
5	Fuel return hose No.2 (See Fuel Return Hose No.2 Installation Note.)
6	Fuel main hose No.2 (See Fuel Main Hose No.2 Installation Note.)
7	Fuel return hose No.3 (See Fuel Return Hose No.3 Installation Note.)
8	Fuel return hose No.4 (See Fuel Return Hose No.4 Removal Note.) (See Fuel Return Hose No.4 Installation Note.)
9	Lower case (See Lower Case Removal Note.) (See Lower Case Installation Note.)