High Pressure Fuel Pump Repair Procedures

Removal

When removing the high-pressure fuel pump, high-pressure fuel line, delivery pipe, or injector, injury may occur due to high-pressure fuel leakage. Do not perform repair work 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")

   When the fuel pump fuse is removed, a diagnostic trouble code (DTC) may be set. Clear the DTC from the ECM after completing the "Fuel Line Residual Pressure Release" procedure.

3. 3
   Remove the air cleaner and air intake hose. (Refer to Engine Mechanical System - "Air Cleaner")
4. 4
   Remove the pump cover (A).

   

5. 5
   Disconnect the fuel pressure control valve connector (A).

   

6. 6
   Disconnect the quick connector (A) of the fuel supply tube using the clip removal tool.

   

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

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

7. 7
   Remove the high pressure fuel tube.

   1. Remove the set nut (B) from the high-pressure fuel pump using the special service tool [SST No.: 09314-3Q100 or 09314-27130].
   2. Remove the set nut (C) from the delivery pipe using the special service tool [SST No.: 09314-3Q100].
   3. Remove the purge control solenoid valve. (Refer to Engine Control System - "Purge Control Solenoid Valve")
   4. Remove the functional block mounting bolts (D), then remove the high-pressure fuel tube.
8. 8
   Remove the mounting bolts (E) and remove the high-pressure fuel pump from the cylinder head.

   Loosen the two bolts alternately in small steps (0.5 turn each). If one of the two bolts is fully removed while the other remains installed, the cylinder head surface may be damaged by the pump spring tension.

   

   

   

Installation

Make sure the low-pressure fuel hose quick connector (A) is fully connected to the high-pressure fuel pump until a confirmation click is heard. Make sure again that the low-pressure fuel hose is fully connected to the high-pressure fuel pump by pulling on the connection. Install the clip cover (A) to fully secure the quick connector. Make sure to install the high-pressure fuel pipe (B) to the specified torque. Carefully check all fuel line connections for leaks when starting the engine.

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.

Do not reuse the bolt.

Do not reuse the high-pressure fuel pipe.

When tightening the high-pressure fuel pump mounting bolts, tighten them alternately in small steps (0.5 turn each) after tightening them by hand.

Install the component with the specified torque. First tighten the fasteners fully by hand until they are seated to install them in position, then tighten fully to the specified torque using a torque wrench. If bolts or nuts are tightened out of line with the bolt holes or fittings, fuel leaks may occur 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.

1. Install in the reverse order of removal.

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

   High-pressure fuel pump mounting bolt: 12.8 ~ 14.7 N·m High-pressure fuel line mounting nut: 26.5 ~ 32 N·m High-pressure fuel line functional block mounting bolt: 7.8 ~ 11.8 N·m