PY01-13-35Z

1. [
2. {
3. "step": 1,
4. "title": "High-Pressure Fuel Pressure Relief & Battery Safety",
5. "instruction": "Disconnect negative battery terminal. Remove fuel pump fuse and crank engine for 5 seconds to depressurize the 200-bar fuel rail. Allow turbocharger assembly to cool completely."
6. },
7. {
8. "step": 2,
9. "title": "Engine Cosmetic Cover & Intake Ducting Disassembly",
10. "instruction": "Remove Skyactiv-G engine cover and unbolt upper intercooler pipe and bracket assemblies to expose the high-pressure fuel pump mounted on the cylinder head cover."
11. },
12. {
13. "step": 3,
14. "title": "Electrical Connector & Fuel Line Detachment",
15. "instruction": "Disconnect the fuel pressure control valve connector. Using a 17mm flare nut wrench, loosen high-pressure steel delivery pipe union nuts (counter-holding pump fitting). Release low-pressure supply line clamp."
16. },
17. {
18. "step": 4,
19. "title": "Camshaft Base Circle Alignment & Pump Removal",
20. "instruction": "Turn crankshaft pulley clockwise until the high-pressure pump camshaft drive lobe is at base circle to minimize spring load. Alternately loosen mounting bolts 1/2 turn at a time and remove pump."
21. },
22. {
23. "step": 5,
24. "title": "Roller Tappet Inspection & New Pump Installation",
25. "instruction": "Inspect roller tappet inside head bore for scoring or surface fatigue. Lubricate new pump O-ring with fresh synthetic oil. Place pump square on head and torque bolts alternately to 14 N·m."
26. },
27. {
28. "step": 6,
29. "title": "High-Pressure Tube Torquing & Diagnostic Fuel Pressure Test",
30. "instruction": "Thread high-pressure tube nuts by hand, then torque flare nuts to 28 N·m. Reinstall intercooler ducting. Cycle ignition key ON-OFF 3 times, inspect for fuel leaks, and verify actual fuel rail pressure via OBD2."
31. }
32. ]

Common diagnostic trouble codes (DTCs) triggered when this common rail injector experiences wear, circuit faults, or calibration drift: