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Fuel tank
Withdrawal procedure
Attention! Smoking or the use of open flame in places where work is done on the fuel system is not allowed. When performing work on the fuel
system, the negative battery cable should be disconnected, except for those checks where battery voltage is required.
1. Disconnect the negative battery cable.
2. Drain fuel from tank. Ensure the fuel level in the tank is less than 1/4 of the full. If necessary, empty the fuel tank at least to this level.
3. Raise and support the vehicle.
4. Remove front silencer. See Section 1G1, Exhaust System - 2.0 Diesel.
5. Disconnect the fuel pump connector on the right side of the fuel tank.
6. Disconnect the filler pipe from the fuel tank.
7. Disconnect the fuel supply and return lines located near the right front side of the fuel tank.
8. Remove rear drive axle, if equipped. See Section 3B, Rear Drive Axle.
9. Support fuel tank.
10. Remove the fuel tank clamp retaining screws.
11. Remove the fuel tank tapes.
12. Gently push and move the front of the fuel pump down, tilting the back of the fuel pump up.
13. Remove the fuel tank.
Installation procedure
1. Reinstall the fuel tank.
2. Install the fuel tank clamps.
Tighten
Tighten the fuel tank clamp retaining bolts to 20 N • m (15 lb-ft).
3. Connect the fuel supply and return lines located near the right front side of the fuel tank.
4. Connect the fuel filler pipe.
5. Connect the fuel pump connector on the right rear side of the fuel tank.
5. Disconnect the electrical connector for the backup fuel pump assembly.
6. Install the backup ring pump EN-48278 lock ring disassembly / assembly tool to the backup fuel pump and turn it counterclockwise.
7. Remove the lock ring of the backup fuel pump.
Note: Be careful not to damage the fuel sensor when dismantling the fuel pump assembly from the fuel tank.
8. Remove the backup fuel pump assembly and O-ring from the fuel tank.
Note: O-ring must not come in contact with fuel.
9. Disconnect the connecting hose connecting the main fuel pump to the backup fuel pump from the backup fuel pump.
10. Disconnect the electrical connector from the main fuel pump.
11. Disconnect the fuel supply and return pipes.
12. Install the tool for dismounting / mounting the lock rings of the main fuel pump EN-48279 on the main fuel pump and turn it counterclockwise.
13. Remove the locking ring of the main fuel pump.
Note: Be careful not to damage the fuel sensor when dismantling the fuel pump assembly from the fuel tank.
14. Remove the main fuel pump assembly and O-ring from the fuel tank.
Note: O-ring must not come in contact with fuel.
Installation procedure
1. Clean all contact surfaces under the seals on both fuel pumps and in the fuel tank.
Note: To simplify the connection of the connecting hose connecting the main fuel pump to the backup fuel pump, first install the main fuel
pump assembly.
Note: Make sure that the arrow on the main fuel pump assembly matches the arrow on the fuel tank.
Note: Be careful not to damage the fuel sensor when installing the fuel pump assembly in the fuel tank.
Attention! Do not reuse the O-ring on the main fuel pump.
2. First put the new O-ring of the main fuel pump and the main fuel pump in the fuel tank in the same position as before dismantling.
3. Remove the connecting hose connecting the main fuel pump and the backup fuel pump from the backup fuel pump assembly.
4. Connect the connecting hose connecting the main fuel pump to the backup fuel pump to the backup fuel pump.
Note: Verify that the arrow on the backup fuel pump assembly assembly matches the arrow on the fuel tank.
Note: Be careful not to damage the fuel sensor when installing the fuel pump assembly in the fuel tank.
Attention! Do not reuse the O-ring of the backup fuel pump.
5. Place the new backup fuel pump o-ring and the backup fuel pump in the fuel tank in the same position as before dismantling.
6. Install the backup fuel pump lock ring by turning the EN-48278 lock ring removal / mounting tool clockwise.
7. Connect the electrical connector to the backup fuel pump.
8. Install the lock ring of the main fuel pump by turning the lock ring removal / mounting tool for the main fuel pump EN-48279 clockwise.
9. Connect the electrical connector to the main fuel pump.
10. Connect the supply and return fuel lines.
11. Install covers for access to primary and backup fuel pumps.
12. Connect the negative battery cable.
13. Check fuel pump performance.
14. Set the rear seats to their original position.
Fuel filter / Water in fuel sensor / Heater and fuel temperature sensor
Necessary equipment
EN-48303 Fuel Filter Housing Holder
EN-48304 Tool for removing / mounting the fuel filter lock
Withdrawal procedure
Attention! Smoking or the use of open flame in places where work is done on the fuel system is not allowed. When performing work on the fuel
system, the negative battery cable should be disconnected, except for those checks where battery voltage is required.
1. Disconnect the negative battery cable.
2. Remove the decorative cover. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. Remove the air filter assembly. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Disconnect the inlet / outlet fuel line from the fuel filter.
5. Disconnect the connector for the heater and fuel temperature sensor (a).
6. Disconnect the fuel water sensor connector (b).
7. Remove the fuel filter assembly from the bracket up.
8. Install the EN-48303 filter housing holder (a) and the EN-48304 (b) fuel filter lock / disassemble / mount fixture to the fuel filter assembly.
9. Rotate the EN-48304 fuel filter lock / disassemble / mount tool counterclockwise.
10. Remove the fuel filter lock (a).
11. Remove the fuel filter cover (b) together with the o-ring (c).
12. Remove the fuel filter (d) in the fuel filter housing (e).
Note: The fuel filter cover is made with a heater and fuel temperature sensor as a whole. In the same way, the fuel filter housing is made as a
unit with the water-in-fuel sensor.
Attention! If the fuel filter element remains in the air for more than a minute, then it will not be possible to reuse it.
Water drainage procedure
1. Turn the fuel drain screw counterclockwise.
2. After completion, turn the shutter screw in the opposite direction.
3. Pump up fuel. See “Pumping Fuel” in this section.
I t ll ti d
Installation procedure
Attention! Do not touch the fuel filter element with your hands. A damaged element affects the performance of the engine and the failure of the
injection pump and nozzles.
1. Install the fuel filter (d) in the fuel filter housing (e).
2. Install the fuel filter cover (b) together with the o-ring (c).
3. Install the fuel filter lock (a) using the EN-48303 filter housing holder and the EN-48304 fuel filter lock / unlock tool.
Tighten
Tighten the fuel filter lock to 30 N • m (22.1 lb-ft).
4. While holding the injection pump coupling (a), unscrew the nut (M14) securing the fuel line to the common fuel rail.
Attention! In order to avoid fuel spillage or damage from the injection pump adapter, hold the injection pump adapter with tools and unscrew the
nut (M14) securing the fuel line to the common fuel rail. And then, immediately after removing the fuel lines, put the cap on the connector of the
injection tube to avoid dust contamination. Even a small amount of dust can clog the nozzles.
5. Unscrew the nut securing the fuel line to the common fuel rail (M17).
6. Unscrew the bolt securing the fuel line to the common fuel rail from the thermostat housing.
7. Remove the pipe from the fuel pipe to the common fuel rail and the pipe from the fuel pipe to the nozzles.
Attention! Immediately after removing the threaded connections, put the caps on the threaded connections of the pipes of the common fuel rail to
avoid dust contamination. Even a small amount of dust can clog the nozzles.
Installation procedure
Important: Fuel lines must not be reused When reused contaminated tubes can damage nozzles or leak tubes
Important: Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Do not wipe with wipes inside the nozzle couplings, injection pump and threaded joints of the common fuel rail tubes. If contaminated,
wipe the dusty area with oiled paper.
1. If the threaded connection of the common fuel rail is dirty, clean with oiled paper.
2. Loosen the nozzle bracket bolts. See “Injector” in this section.
3. Install the fuel lines between the injectors and the common fuel rail and tighten the nuts by hand.
Attention! Do not tighten the fuel line nuts with a tool.
4. Tighten the nozzle bracket bolts.
Tighten
Tighten the nozzle bracket bolt to 28 N • m (20.7 lb-ft).
5. While holding the nozzle adapter sleeve (a), tighten the nut (M14) securing the fuel line to the nozzle.
Tighten
Tighten the fuel line to the injector nut (M14) to 27 N • m (19.9 lb-ft).
7. Install the fuel line between the common rail and the injection pump and tighten the nuts by hand.
Attention! Do not tighten the fuel line nuts with a tool.
8. While holding the injection pump coupling (a), tighten the nut (M14) securing the fuel line to the common fuel rail.
Tighten
Tighten Nut (M14) securing the fuel line to the common rail to 20 N • m (14.8 lb-ft).
2. Remove the intake manifold. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. Remove the timing belt. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Remove the power steering pump. Follow section 6B, Power steering pump.
Attention! Immediately after removing the fuel lines, put the cap on the squeeze sleeve of the injection pump to avoid dust contamination. Even a
small amount of dust can clog the nozzles.
5. Remove the injection pump sprocket together with the segment key.
6. Remove the injection pump assembly.
Installation procedure
Important: Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Do not blow out air from the spray gun inside the nozzle couplings, injection pump, and threaded joints of the common fuel rail tubes. If
contaminated, wipe the dusty area with oiled paper.
Attention! Do not wipe with wipes inside the nozzle couplings, injection pump and threaded joints of the common fuel rail tubes. If contaminated,
wipe the dusty area with oiled paper.
1. Install the injection pump assembly.
Tighten
Tighten the injection pump bolts to 30 N • m (22.1 lb-ft).
2. Insert the segment key into the groove of the drive shaft of the injection pump.
3. Install the injection pump sprocket.
4. Tighten the injection pump sprocket nut by hand.
5. Combine the mark on the sprocket and the mark on the rear cover of the timing belt.
6. Install and align the timing belt. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
7. Install the injection pump sprocket nut.
Tighten
Tighten the fuel pump sprocket nut to 70 N • m (51.6 lb-ft).
6. Remove the high pressure fuel lines. See "High Pressure Fuel Supply Pipelines" in this section.
7. Remove the common rail assembly.
Attention! Immediately after removing the fuel lines, put the cap on the threaded connections of the pipes of the common fuel rail to avoid dust
contamination. Even a small amount of dust can clog the nozzles.
Installation procedure
Important: Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Do not blow out air from the spray gun inside the nozzle couplings, injection pump, and threaded joints of the common fuel rail tubes. If
contaminated, wipe the dusty area with oiled paper.
Attention! Do not wipe with wipes inside the nozzle couplings, injection pump and threaded joints of the common fuel rail tubes. If contaminated,
wipe the dusty area with oiled paper.
1. Install the common fuel rail assembly.
Tighten
Tighten
Tighten the common rail fuel rail mounting bolts to 25 N • m (18.4 lb-in).
2. Install fuel lines to a common fuel rail. See "High Pressure Fuel Supply Pipelines" in this section.
3. Connect the pressure sensor connector in the common fuel rail.
4. Connect the fuel rail regulator connector.
5. Pump up fuel. See “Pumping Fuel” in this section.
Installation procedure
Attention! Do not blow out air from the spray gun inside the nozzle couplings, common fuel rail and injection pump. If contaminated, wipe the
dusty area with oiled paper.
Attention! Do not wipe with wipes inside the nozzle couplings, common fuel rail and injection pump. If contaminated, wipe the dusty area with oiled
paper.
1. Inspect and clean the threads and sealing surface of the ramp.
2. Inspect and clean the threads and sealing surface of the ramp pressure sensor.
3. Lubricate the thread (a) and the cutting edge (b) of the rail pressure sensor with Ft1v27 (only a thin film of grease).
Installation procedure
Important: This common rail fuel rail regulator and o ring must not be reused
Important: This common rail fuel rail regulator and o-ring must not be reused.
Attention! Do not blow out air from the spray gun inside the nozzle couplings, injection pump, and threaded joints of the common fuel rail tubes. If
contaminated, wipe the dusty area with oiled paper.
Attention! Do not wipe with wipes inside the nozzle couplings, injection pump and threaded joints of the common fuel rail tubes. If contaminated,
wipe the dusty area with oiled paper.
1. Inspect and clean the threads and sealing surface of the ramp.
2. Inspect and clean the threads (a) and the cutting edge (b) of the common rail regulator.
Note: Inspect the sealing surfaces of the DRV and the ramp or high pressure pump. Only concentric grooves are allowed. Any cuts in the radial
direction are not allowed. Inspect Torx screws or shoulder for any damage.
Installation procedure
1. Install the fuel return assembly.
2. Connect the return hose of the common fuel rail.
Important: Press the nozzle return tube vertically into the nozzle with your hand from top to bottom until you hear a click of the connecting
Important: Press the nozzle return tube vertically into the nozzle with your hand from top to bottom until you hear a click of the connecting
piece that is in place.
3. Connect the injection pump return hose.
nozzle
Necessary equipment
EN-48357 Injector Remover
Attention! Smoking or the use of open flame in places of work on the fuel system is not allowed. When working on the fuel system, the negative
battery cable must be disconnected, except for those checks where battery voltage is required.
Withdrawal procedure
1. Disconnect the negative battery cable.
2. Remove the high pressure fuel lines. See "High Pressure Fuel Supply Pipelines" in this section.
3. Remove the injector return hoses. See “Return Fuel Assembly” in this section.
9. If the nozzle is stuck to the cylinder head, use the EN-48357 nozzle remover.
Installation procedure
Attention! The nozzle washer must not be reused.
1. Inspect and clean nozzle and nozzle tip.
Attention! Do not wipe the nozzle tip area. This may damage the nozzle opening.
2. Install the nozzle with a new washer.
3. Insert the nozzle bracket into the groove of the nozzle.
4. Tighten the nozzle bracket bolt.
Tighten
Tighten the nozzle bracket bolt to 28 N • m (20.7 lb-ft).
4. Remove the three bolts securing the accelerator pedal (APM) from the accelerator and the brake pedal bracket.
Installation procedure
1. Install the accelerator pedal mounting bolts (APM) to the accelerator and brake pedal bracket.
Tighten
Tighten the mounting bolts of the accelerator pedal assembly to 9 N • m (80 lb-in).
2. Connect the accelerator pedal connector (APM) and securely install the retaining clamp.
Mass Air Flow (MAF) Sensor
Removal / Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the MAF sensor connector.
3. Remove the MAF sensor.
7. Remove the bracket for the decorative cover. See "Vacuum Pump" in this section.
8. Remove the engine wiring harness bracket. See "Vacuum Pump" in this section.
9. Remove the exhaust pipe for the exhaust gas recirculation cooler.
10. Disconnect the hose from the expansion tank to the water pipe.
11. Disconnect the hose from the heater to the water pipe.
12. Unscrew the water pipe mounting bolt from the front of the engine block.
Installation procedure
1. Install the exhaust gas recirculation cooler inlet pipe to the exhaust manifold.
2. Install the exhaust gas recirculation cooler together with the engine wiring harness bracket.
Tighten
Tighten Tighten the exhaust gas recirculation cooler intake manifold retaining nuts to 33 N • m (24.3 lb-ft).
Tighten the exhaust gas recirculation cooler bolt to 20 N • m (14.8 lb-ft).
3. Install EGR valve.
4. Screw the water pipe mounting bolt into the engine block.
Tighten
Tighten the exhaust gas recirculation valve mounting nuts (to the exhaust gas recirculation cooler) to 20 N • m (14.8 lb-ft).
Tighten the exhaust gas recirculation valve bolts (to the exhaust gas recirculation inlet pipe) to 20 N • m (14.8 lb-ft).
Tighten the water pipe mounting bolt (M6) to 9 N • m (79.7 lb-in).
Tighten the water pipe mounting bolt (M8) to 20 N • m (14.8 lb-in).
5. Install the exhaust pipe for the exhaust gas recirculation cooler.
6. Screw the water pipe mounting bolt into the front of the engine block.
Tighten
Tighten Tighten the exhaust gas recirculation cooler exhaust pipe bolts and nuts to 20 N • m (14.8 lb-ft).
Tighten the water pipe mounting bolt (M8) to 20 N • m (14.8 lb-in).
Turbocharger
Removal / Installation Procedure
Attention! Ensure that all components are cool. Then do the work.
1. Disconnect the negative battery cable.
2. Remove the decorative cover. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. Remove the hoses and air ducts of the charge air system. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Remove the crankcase ventilation valve (PCV) and adapter. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
5. Remove the preliminary catalytic converter. See Section 1G1, Exhaust System - 2.0 Diesel.
6. Disconnect the turbocharger drive connector.
7. Remove the oil feed pipe to the turbocharger impeller bearing.
8. Disconnect the oil exhaust hose from the turbocharger impeller bearing.
9. Remove the turbocharger.
Installation procedure
1. Install the turbocharger to the exhaust manifold.
2. Install the oil supply pipe to the turbocharger impeller bearing.
3. Connect the oil exhaust hose from the turbocharger impeller bearing.
Tighten
Glow plug
Removal / Installation Procedure
Attention! Ensure that all components are cool. Then do the work.
1. Disconnect the negative battery cable.
2. Remove the decorative cover. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. Remove the hoses and air ducts of the charge air system. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Remove the crankcase ventilation valve (PCV) and adapter. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
5. Remove the heat shield of the glow plug.
6. Disconnect the glow plug harness.
5. When replacing a diesel particulate filter (DPF), reset the diesel particulate filter (DPF) EEPROM using a scan tool.
Recovery Order
Attention! During recovery of a diesel particulate filter (DPF), the exhaust system is very hot. To prevent fire or damage, raise the vehicle on the lift
and create an inaccessible area around the exhaust system.
1. Warm up the engine.
2. Restore diesel particulate filter (DPF) using a scan tool.
Installation procedure
1. Install the ECM bracket.
Tighten
Tighten the ECM controller bracket retaining nuts to 15 N • m (11.1 lb-ft).
2. Install the ECM.
3. Connect the ECM connectors.
Important: When replacing the ECM, reprogram the ECM using the scan tool.
Set engine oil life
Reset EEPROM for ZFC (Zero Fuel Correction)
Reset EEPROM of diesel particulate filter (DPF)