High Pressure Fuel Pump Repair Procedures

Removal

Whenever the high pressure fuel pump, fuel delivery pipe, delivery pipe or injector is removed immediately after the engine is turned off, injury may be caused by high pressure fuel spray. Release the residual pressure in the high pressure fuel line by referring to the "Fuel Residual Pressure Release Procedure" before removing any high pressure fuel system components.

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

   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
   Disconnect the fuel pressure control valve connector (A) and the fuel supply tube quick connector (B).

   

   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.

4. 4
   Remove the high pressure fuel tube.

   1. Remove the high pressure pipe flange nut in the order of A, B using the Special Service Tool [SST No.: 09314-3Q100].

      

   2. Disconnect the engine coolant temperature sensor connector.
   3. Remove the function lock set bolt (C).

      

5. 5
   Loosen the set bolts (D) 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. After connecting, be sure to check again that the low-pressure fuel hose is fully connected to the high-pressure fuel pump by pulling on it. Make sure to install the high-pressure fuel pipe (B) to the specified torque. Since fuel leakage may cause a fire, carefully check all connections of the fuel line 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] 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