COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

id0114z7803900

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.
•  Do not let foreign matter get into the injection pipe to prevent clogging. In addition, always tighten the injection pipe to the specified torque.
Note
•  If the common rail is replaced, perform the “Fuel Injection Amount Learning”.

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 injection pipes (fuel injector side) and the injection pipe (supply pump side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove in the order shown in the figure.

6.  Install in the reverse order of removal.

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

ac5wzw00008526

1
Fuel pressure sensor connector
2
Fuel pressure relief valve connector
3
Fuel return hose No.4
(See Fuel Return Hose No.4 Installation Note.)
4
Common rail
(See Common Rail Installation Note.)


Common Rail Installation Note

1.  Temporarily tighten the common rail.

am3zzw00021105

2.  Temporarily tighten the new injection pipe (supply pump side).

3.  Temporarily tighten the new injection pipes (fuel injector side).

4.  Temporarily tighten the fuel return pipe (supply pump side).

5.  Tighten the new clip. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Tighten the injection pipe (supply pump side) bracket.

Injection pipe (supply pump side) bracket tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

7.  Tighten the injection pipe (supply pump side) and the injection pipes (fuel injector side) on the common rail side.

Tightening torque for injection pipe (supply pump side) and injection pipe (fuel injector side)
32—42 N·m {3.3—4.2 kgf·m, 24—30 ft·lbf}

8.  Tighten the injection pipe (supply pump side) and the injection pipes (fuel injector side) on the fuel injector side.

Tightening torque for injection pipe (supply pump side) and injection pipe (fuel injector side)
32—42 N·m {3.3—4.2 kgf·m, 24—30 ft·lbf}

9.  Tighten the common rail.

Common rail tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

10.  Tighten the fuel return pipe (supply pump side).

Fuel return pipe (supply pump side) tightening torque
Supply pump side: 18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}
Lower case side: 20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}


Fuel Return Hose No.4 Installation Note


Lower case side

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

ac5wzw00008527
ac5wzw00008528


Common rail side

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

ac5wzw00008529