High pressure fuel pump

Repair Procedures

Removal

1. 1
   Release the residual fuel pressure in the fuel line. (Refer to Fuel System - "Release Residual Fuel Pressure in Line")
2. 2
   Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
3. 3
   Remove the high-pressure fuel pump insulator (A).

   

4. 4
   Remove the control wiring harness (A).

   

5. 5
   Remove the fuel line mounting bolts (A).

   

6. 6
   Disconnect the high-pressure fuel supply control valve connector (A) and the quick connector of the pressurized fuel tube (B).

   

7. 7
   Remove the high-pressure fuel tube. (Refer to Fuel System – "Fuel Line")
8. 8
   Remove the mounting bolts (A), then remove the high-pressure fuel pump (B) from the cylinder head assembly. High-pressure fuel pump mounting bolt: 12.8–14.7 N·m

   Loosen the two bolts alternately in small steps (0.5 turn each). When 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 spring tension of the pump.

Installation

Make sure the quick-connect fitting of the low-pressure fuel hose (A) is fully connected to the high-pressure fuel pump until it locks. Double-check the full connection of the low-pressure fuel hose to the high-pressure fuel pump by pulling on it after connecting. Be sure to install the high-pressure fuel tube (B) to the specified torque. Since fuel leakage may cause a fire, carefully inspect all fuel line components for leaks when starting the engine.

Before installing the high-pressure fuel pump, set the roller tappet to the bottom-most position by turning the crankshaft. Otherwise, the mounting bolts may break due to the tension of the pump spring. Do not reuse the bolts. Do not reuse the high-pressure fuel line. When tightening the high-pressure fuel pump mounting bolts, first tighten them by hand, then tighten them to the specified torque in small steps (0.5 turn each). Install the component to the specified torque. First secure the fasteners in place by hand-tightening them. Then tighten them to the specified torque using a torque wrench. Bolts or nuts tightened out of alignment with the corresponding bolt holes or fittings may cause fuel leakage due to damaged threads. Note that internal damage may occur if the component is dropped. In this case, 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.

Use the Special Service Tool [SST No.: OK353-F6100] to install the high-pressure fuel pump.

1. Install in the reverse order of removal.