High-Pressure Fuel Pump

Installed High-Pressure Fuel Pump

Before removal, make a mark on the pump at the indicated location.
If installing a new high-pressure fuel pump, check all injection system components.

Removal

PROCEDURE
1. Drain the coolant from the cooling system.
2. Disconnect the accelerator cable from the high-pressure fuel injection pump.
3. Disconnect the following hoses: the two bypass hoses and, if equipped, the air conditioning hose.
4. Remove the injection inlet pipe. It is secured with a banjo-type fitting.
5. After loosening the clamp, disconnect the fuel return hose.
6. Remove the bolt and nut securing the heater pipe bracket.
7. Disconnect the four injection pipes. To do this, remove the nuts securing the four pipes to the intake manifold, loosen the clamps, and loosen the union nuts. Use a flare nut wrench with a slot that allows the pipe to pass through. Do not round off the flats of the union nuts.
8. Remove the timing belt. The high-pressure fuel injection pump drive gear is removed with it.
9. Check the alignment mark on the water pump. If the marks are not visible, rotate the pump and its mounting points as specified. Adjusting the high-pressure fuel injection pump is complex work and is best performed at a workshop. However, installing the pump with the alignment marks aligned guarantees easy engine starting. Adjust the pump only if the engine does not run as it should.
10. Remove the two nuts and bolts, remove the rear pump bracket (four bolts), and remove the pump.

Installation

PROCEDURE
1. Position the pump correctly and rotate it so that the marks on the pump and on the water pump are aligned as shown in the illustration. Tighten both nuts and the bolt by hand. Final tightening is done after installing the rear bracket. Install the bracket and tighten the four bolts to 20 N·m. Then tighten the bolts and nuts on the other side to the same torque.
2. Install the high-pressure fuel injection pump drive gear and the timing belt, and install the timing belt cover.
3. Connect the inlet pipe to the high-pressure fuel injection pump. Install new sealing washers and secure the pipe with the banjo bolt. Install the fuel hose and secure it with a clamp.
4. Secure the fuel return pipe in the same way, but tighten the union nut. Install the hose and secure it with a clamp.
5. Tighten the four injection pipes.
6. Connect the accelerator cable. Make sure the fuel injection pump moves to the full throttle position and returns to the idle position.
7. Perform the remaining work in reverse order.