Fuel Filter>Replacement

Replacement
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
3. Remove the battery.
(Refer to Engine Electrical System - "Battery")
4. Remove the ECM.
(Refer to Engine Control System - "ECM")
5. Disconnect the water sensor connector (A), the heater connector (B).

6. Disconnect the fuel inlet tube (A) quick-connector and the fuel outlet tube (B) quick-connector.

7. Unscrew the fuel filter installation nuts (A), and then remove the fuel filter assembly (B) from the
vehicle.

Tightening torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

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Fuel Filter>Replacement

8. Remove the water sensor (A).

9. Remove the fuel filter assembly from the bracket after removing the bracket nuts (C) and bolt (B),
replace it with a new one, and then install the fuel filter assembly in accordance with reverse of
above steps.

Tightening torque:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

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Fuel Filter>Replacement

1. Filter body
2. Fuel heater
3. Bracket
4. Fuel filter
5. Water sensor

When replacing the fuel filter, must replace the O-ring.

10. Bleed air in low pressure fuel circuit.
(Refer to Fuel Delivery System - "Bleeding Air in Low Pressure Fuel Circuit")
11. Start the engine and check that there is any leak on the low pressure fuel circuit including the fuel
filter.

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Air Cleaner>Removal

Removal and Installation

1. Remove the engine cover.
2. Disconnect the battery negative terminal.
3. Remove the air duct (A).
4. Disconnect the MAFS (Mass Air Flow Sensor) connector & IATS (Intake Air Temperature Sensor)
Connector (B).
5. Disconnect the breather hose (C).
6. Remove the intake hose (D) and air cleaner assembly (E).

Tightening torque
Hose clamp :
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Air cleaner bolts :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

When installing the air intake hose, confirm the assembly mark of hose to that of
turbocharger.

7. Install in the reverse order of removal.

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Battery>Removal

Removal and Installation

1. Disconnect the battery terminals (A). The negative terminal first.

Tightening torque
(+) terminal:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
(-) terminal:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)

2. Remove the battery insulation pad (A).

3. Remove the battery mounting bracket (B) by loosening the mounting bolt and then remove the
battery (C).

Tightening torque :
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

4. Remove the air duct and air cleaner assembly.

(Refer to Engine Mechanical System - "Air Cleaner")
5. Remove the ECM (B) after disconnecting the ECM connectors (A).

Tightening torque
ECM bracket bolts & nut :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

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Battery>Removal

6. Disconnect the battery positive cable (A) and then remove the battery tray (B).

Tightening torque :
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

7. Installation is the reverse order of removal.

When installing the battery, fix the mounting bracket on the tray correctly.

• ISG (Idle stop & go) system equipped vehicle always use the AGM battery only. If flooded
battery has installed, this can potentially lead to engine electrical trouble or ISG system
error.
• Replace same capacity of the AGM battery.

Ensure an AGM battery is fitted.

In all cases, an AGM battery must be installed and registered in the vehicle for the ISG
function to work perfectly.
The vehicle with the new battery must be placed in the ignition switch OFF and door closed,
hood switch OFF state for at least 4 hours.
ISG system’s stabilization may take 4 hours after new battery installation.
ISG function is operates about 4 hours later and 2 times cranking by user.
But first 25 times, the ISG function can operates regardless of ISG system stability for ISG
function operating check.

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Battery>Removal

Do not open the AGM battery.

The AGM battery must not be opened under any circumstances as the introduction of
oxygen from the air will cause the battery to lose its chemical equilibrium and rendered non-
operational.

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Engine Control Module (ECM)>Replacement

Replacement

When replacing the ECM, the vehicle equipped with immobilizer must be performed the
procedure as below.
[In the case of installing used ECM]
1) Perform "Neutral mode" procedure with GDS.
(Refer to Body Electrical System - "Immobilizer System")
2) Insert the key and turn it to the IGN ON and OFF position.
Then the ECM key register process is completed automatically.
[In the case of installing new ECM]
– Insert the key and turn it to the
IGN ON and OFF position.
Then the ECM key register process is completed automatically.
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the ECM connector (A).

3. Unscrew the ECM mounting bolts (A) and remove the ECM & bracket assembly.

4. Remove the ECM from bracket after removing nuts (A).

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Engine Control Module (ECM)>Replacement

5. Install a new ECM.

ECM bracket installation bolt:

19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
ECM installation nut:
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

6. Connect the negative(-) battery cable.

7. Perform "ECM Change" procedure [With DPF].
(1) Turn ignition switch OFF.
(2) Connect a GDS Data Link Connector (DLC).
(3) Turn ignition switch ON.
(4) Select "Vehicle, Model year, Engine, System".
(5) Select "Vehicle S/W Management".
(6) Select "Component Change Routine".
(7) Select "ECU Change".
(8) Input the mileage in odometer.

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Engine Control Module (ECM)>Replacement

(9) Confirm the "Complete" message and then turn ignition switch OFF.

(10) Wait for more than 10 seconds, and then turn ignition switch ON.
8. Perform "Injector Specific Data Input" procedure.
(Refer to Engine Control System - "Injector")
9. Perform "Key Teaching " procedure.
(Refer to Body Electrical System - "Immobilizer System")

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