17/07/2019 FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.

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FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Warning
• Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. If fuel comes into
contact with the skin and eyes it will cause irritation. To prevent this, always perform the “Fuel Line Safety Procedure” referring to the “BEFORE
REPAIR PROCEDURE”.
• 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 install the injection pipe to the specified tightening torque.

Note
• If the fuel injector is replaced, perform the fuel injector data reset procedure.

Operation After Replacing Fuel Injector

1. If the fuel injector is replaced, perform the following procedure.

STEP ACTION PAGE/CONDITION

1 Perform fuel injector code programming. (See FUEL INJECTOR CODE PROGRAM [SKYACTIV-D 2.2].)
2 Switch the ignition off. —
3 Perform fuel injector data reset procedure. (See FUEL INJECTOR DATA RESET [SKYACTIV-D 2.2].)
4 Switch the ignition off. —
5 Clear the DTCs. (See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [SKYACTIV-D 2.2].)
6 Switch the ignition off. —
7 Wait for 20 s. —
8 Switch the ignition ON (engine off). —
9 Perform KOEO self-test procedure. (See KOEO/KOER SELF TEST [SKYACTIV-D 2.2].)
10 Start the engine. —
11 Verify that the check engine light does not illuminate. —
12 Perform KOER self-test procedure. (See KOEO/KOER SELF TEST [SKYACTIV-D 2.2].)
13 Perform fuel injector injection amount correction. (See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 2.2].)
14 Switch the ignition off. —
15 Clear the DTCs. (See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [SKYACTIV-D 2.2].)
16 Switch the ignition off. —

Fuel injector 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. Disconnect the CMP sensor connector.

5. Remove the injection pipe (fuel injector side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6. Remove in the order shown in the figure.

7. Install in the reverse order of removal.

8. Refer to the “AFTER SERVICE PRECAUTION” and perform the fuel hose installation procedure and fuel line air bleeding. (See AFTER SERVICE
PRECAUTION [SKYACTIV-D 2.2].)

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1 Fuel injector connector

2 Fuel return pipe (fuel injector side)
3 Fuel injector bracket
Fuel injector
4 (See Fuel injector removal note.)
(See Fuel injector installation note.)
(See Operation After Replacing Fuel Injector.)

Fuel injector removal note

Caution
• Do not apply excessive force to the bar to prevent damaging the cylinder head cover which the socket is set to.

1. If it is difficult to remove the fuel injector, use a bar and socket set up as shown in the figure as leverage to lift the fuel injector bracket and then remove the
fuel injector.

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Note
• Set the bar on the socket with the socket as the fulcrum point.

Fuel injector installation note

Note
• Clean the injector hole and the bore using the following procedure and the SSTs (49 0000 203) shown in the figure.

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1 Round wire brush

2 Fleece brush
3 Wire brush
4 Blanking plug
5 Extension bar
6 Flexible shaft
7 Holder

1. Install the blanking plug to the end of the extension bar.

2. Insert the blanking plug into the injector hole, rotate the extension bar counterclockwise, and then block the injector hole using the blanking plug.

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3. Install the round wire brush to the end of the flexible shaft.

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Caution
• Install the holder and clean the bore to prevent damage to the bore.

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4. Connect the flexible shaft installed to the round wire brush to the drill, and clean the bore.

5. Clean the carbon that was cut off using an air gun.

6. Cut (reference: diameter approx. 23 mm) the fleece brush so that it reaches the bottom surface, and install it to the flexible shaft.

Caution
• Clean the bottom surface while verifying the cleaning surface condition. If the bottom surface is cleaned excessively, it could be damaged.

7. Connect the flexible shaft installed to the fleece brush to the drill, and clean the bottom surface.

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8. Clean the carbon that was cut off using an air gun.

9. Insert the extension bar and remove the blanking plug.

10. Clean the injector hole using a wire brush.

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11. Temporarily install the fuel injector and the fuel injector bracket.

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12. Loosen the common rail.

13. Temporarily tighten the new injection pipe (fuel injector side).

14. Tighten the new fuel injector bracket installation nuts using the following procedure.

Caution
• If the fuel injector bracket installation nuts are tightened incorrectly, it could damage the fuel injector bracket and cause gas leakage due to incorrect
installation. To prevent this, tighten the fuel injector bracket installation nuts using the following procedure.

Note
Fuel injector bracket installation nut type A
• A paint mark for tightening to the specified angle is indicated on the fuel injector bracket installation nuts (angle between same colored paint marks
is 230 degrees as shown in figure).

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Fuel injector bracket installation nut type B
• There is a scribe line engraved on the fuel injector bracket installation nut for tightening it to the specified angle. (The angles between the white
paint mark and scribe line A, and between the yellow paint mark and scribe line B are both 230 degrees as shown in the figure)

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• Tighten only the fuel injector bracket installation nuts on the engine rear side to the specified angle.

(1) Temporarily tighten the nut on the engine front side (until nut is seated).

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(2) Completely tighten the nut on the engine front side.

Tightening torque

2.0 N·m {20 kgf·cm, 18 in·lbf}

(3) Loosen the nut on the engine front side 90 degrees.

(4) Temporarily tighten the nut on the engine rear side (until nut is seated).

(5) Completely tighten the nut on the engine rear side.

Tightening torque

2.0 N·m {20 kgf·cm, 18 in·lbf}

(6) Draw a line on the fuel injector bracket at a right angle to the paint mark (either yellow or white) on the nut surface on the engine rear side. (fuel
injector bracket installation nut type A)

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Note
• The drawn line on the fuel injector bracket is the standard angle to which the nut is tightened.

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(7) Draw a line on the fuel injector bracket at a right angle to the center of the scribe line (either A or B) on the surface of the nut on the rear side of
the engine. (fuel injector bracket installation nut type B)

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Note
• The drawn line on the fuel injector bracket is the standard angle to which the nut is tightened.

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(8) Tighten the nut until the paint mark (same color step (6) or (7)) on the nut upper surface on the engine rear side comes to the position of the
drawn line on the fuel injector bracket.

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Note
• After tightening the nut following the procedure, the bolt projections differ as shown in the figure because the fuel injector bracket leans a little. This
is the correct condition and retightening is not required.

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15. Tighten the injection pipes (fuel injector side) on the common rail side.

Tightening torque for injection pipe (fuel injector side)

32—42 N·m {3.3—4.2 kgf·m, 24—30 ft·lbf}

16. Tighten the injection pipes (fuel injector side) on the fuel injector side.

Tightening torque for injection pipe (fuel injector side)

32—42 N·m {3.3—4.2 kgf·m, 24—30 ft·lbf}

17. Tighten the common rail.

Common rail tightening torque

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

18. Tighten the fuel return pipe (fuel injector side) in the order shown in the figure.

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Fuel return pipe (fuel injector side) tightening torque

22—26 N·m {2.3—2.6 kgf·m, 17—19 ft·lbf}

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