SUPPLY PUMP 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.
•  Do not let foreign matter get into the injection pipe to prevent clogging. Always tighten the injection pipe to the specified torque.
•  To prevent fuel leakage, when removing/installing the supply pump, always follow the procedure in the Workshop Manual and perform the procedure.
Note
•  If the supply pump is replaced, perform the “Operation After Replacing Supply Pump”.

Operation After Replacing Supply Pump

1.  If the supply pump is replaced, perform the following procedure.

STEP

ACTION

PAGE/CONDITION
1
Perform supply pump data reset procedure.
(See SUPPLY PUMP DATA RESET [SKYACTIV-D 2.2].)
2
Wait for 20 s.
—
3
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [SKYACTIV-D 2.2].)
4
Maintain the idle status for 30 s with the following condition met.
•  ECT: 60—100 °C {140—212 °F}
—
5
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [SKYACTIV-D 2.2].)


Supply Pump Removal/Installation

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 air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose
•  Air inlet pipe
•  Breather hose
•  Turbocharger air inlet hose
•  Blow-by heater

7.  Set the turbocharger air outlet pipe component aside as a single unit as shown in the figure. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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8.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

9.  Set the water pipe assy aside as shown in the figure.

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10.  Detach the hose clip shown in the figure.

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11.  Detach the wiring harness clips shown in the figure.

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12.  Remove in the order shown in the figure.

13.  Install in the reverse order of removal.

14.  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].)

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1
Clip installation nut
2
Fuel feed pipe
(See Fuel feed pipe removal note.)
(See Fuel feed pipe installation note.)
3
Injection pipe (supply pump side)
(See Injection pipe (supply pump side) removal note.)
(See Injection pipe (supply pump side) installation note.)
4
Clip
5
Bracket
6
Fuel return hose
(See Fuel return hose installation note.)
7
Fuel main hose
(See Fuel main hose installation note.)
8
Suction control valve connector
9
Supply pump
(See Supply pump removal note.)
(See Supply pump installation note.)
(See Operation After Replacing Supply Pump.)
10
Connector No.1
(See Connector No.1 installation note.)
11
Connector No.2
12
Spacer


Fuel feed pipe removal note

1.  Set the harness protector connected to a bracket.

2.  Remove the fuel feed pipe.


Injection pipe (supply pump side) removal note

1.  Remove the injection pipe (supply pump side) as shown in the figure. (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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(1)  Move the flared section.
(2)  Pull out the injection pipe (supply pump side).

2.  Remove the injection pipe (supply pump side).


Supply pump removal note

1.  Remove the supply pump and the suction control valve as a single unit.

2.  Remove the suction control valve from a supply pump.


Connector No.1 installation note

1.  Install the connector No.1 as shown in the figure so that the pipe does not cover the bolt.

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Supply pump installation note

Note
•  In the case of type A, rear camshaft cap performs the following procedures.

1.  I confirm the type of the rear camshaft cap with a difference to shown in the figure.

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Caution
•  To prevent silicone sealant from hardening, adhere the supply pump to the cylinder head within 10 min after applying silicone sealant. Tighten the installation bolts completely soon after adhering.

2.  Apply silicone sealant to the areas shown in the figure.

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Bead thickness
3—7 mm {0.12—0.27}


Fuel main hose installation note

1.  Install fuel main hose as shown in the figure.

Supply pump side

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Lower case side

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Fuel return hose installation note

1.  Install fuel return hose as shown in the figure.

Supply pump side

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Lower case side

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Injection pipe (supply pump side) installation note

1.  Install the injection pipe (supply pump side) as shown in the figure. (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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Fuel feed pipe installation note

1.  Install the fuel feed pipe.

2.  Connect the harness protector to a bracket.