LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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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”.

1. Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

2. Perform the “Fuel Line Safety Procedure” referring to the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

3. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4. Remove the fuel return pipe (supply pump side). (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5. Remove the fuel return pipe (fuel injector side). (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6. Remove in the order shown in the figure.

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1

Fuel main hose

2

Fuel return hose No.1

(See Fuel Main Hose and Fuel Return Hose No.1 Installation Note.)

3

Fuel return hose No.2

(See Fuel Return Hose No.2 Installation Note.)

4

Fuel return hose No.3

(See Fuel Return Hose No.3 Installation Note.)

5

Fuel return hose No.4

(See Fuel Return Hose No.4 Installation Note.)

6

Plug

(See Plug Installation Note.)

7

Lower case

7. Install in the reverse order of removal.

8. Perform the Fuel Hose Installation and Fuel Line Air Bleeding referring to the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

Plug Installation Note

1. Install plug as shown in the figure.

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Fuel Return Hose No.4 Installation Note

Lower case side

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

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Common rail side

1. Install the 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.

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Fuel Return Hose No.2 Installation Note

1. Install fuel return hose No.2 as shown in the figure.

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Fuel Main Hose and Fuel Return Hose No.1 Installation Note

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

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