High Pressure Fuel Pump Repair Procedures

Removal

When removing the high pressure fuel pump, high pressure fuel line, delivery pipe and injector, injury may occur due to high pressure fuel leakage. Do not perform repairs immediately after stopping the engine.

1. 1
   Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. 2
   Release the fuel line residual pressure. (Refer to Fuel System - "Release Fuel Line Residual Pressure")

   A diagnostic trouble code (DTC) may be set when the fuel pump relay is removed. Clear the DTC with GDS after performing "Relieve Residual Fuel Pressure".

3. 3
   Disconnect the quick connector (A) of the fuel feed tube using the clip release tool.
4. 4
   Disconnect the fuel pressure control valve connector (B).

   

   Open the clip cover (B) before disconnecting the quick connector. (If equipped with clip)

   When removing the quick connector using the clip removal tool (A), be careful not to damage the plastic clip (B). If the clip is damaged, fuel may leak due to a poor connection.

5. 5
   Remove the intake manifold. (Refer to Engine Mechanical System - "Intake Manifold")
6. 6
   Remove the high pressure fuel tube.

   1. Remove the bracket mounting bolt (A).

      

   2. Remove the high-pressure fuel pipe flange nut (A, B) in the following order. Use the special service tool [SST No.: 09314-3V100 or 09314-27130] for A and B.
   3. Remove the high-pressure fuel pipe bracket bolt (C).

      

      

7. 7
   Remove the installation bolts (A) and remove the high-pressure fuel pump from the cylinder head.

   Loosen the two bolts alternately by 0.5 turns. If one of the two bolts is fully removed while the other bolt is still installed, the cylinder head surface may be damaged due to the pump spring tension.

Installation

Make sure the quick-connect fitting of the low-pressure fuel hose (A) is fully connected to the high-pressure fuel pump until a click is heard. After connecting the low-pressure fuel hose quick-connect fitting, pull the hose to make sure the low-pressure fuel hose is securely installed to the HP pump. Make sure to install the high-pressure fuel pipe (B) to the specified torque. If there is a leak at the fuel pipe connections, a fire may occur. Inspect all fuel line connections for leaks with the ignition switched on.

Before installing the high-pressure fuel pump, set the roller tappet to the lowest position by rotating the crankshaft. Otherwise, the installation bolts may break due to the pump spring tension.

Make sure foreign material does not get into the high-pressure fuel pump cover insert area.

Do not reuse the bolt.

Do not reuse the high-pressure fuel pipe.

When tightening the high-pressure fuel pump installation bolts, tighten the bolts alternately by 0.5 turns each to the specified torque, using a hand torque wrench.

Install the component with the specified torque.

Be careful not to drop the component, as internal damage may occur. If dropped, inspect it before use.

Apply engine oil to the O-ring (A) of the high-pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion (C) is installed.

1. To install, reverse the removal procedure.

   Use the special service tool [SST No.: (09314-3Q100) or (09314-27130)] to install the high-pressure fuel pipe.

   High-pressure fuel pump bolt: 12.8 ~ 14.7 N·m. High-pressure fuel pipe nut: 29.4 ~ 35 N·m. High-pressure fuel pipe bracket bolt: 9.8 ~ 11.8 N·m