High Pressure Fuel Pump Removal/Installation
HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.0]
WARNING:
- Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE PRECAUTION".
- A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.
CAUTION:
- Do not disassemble the high pressure fuel pump.
- Damage neither sealing surface nor the lock part of the fuel pipe.
- Damage or deformation at the end of the high pressure line pipe may cause fuel leakage.
- Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.
1. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution
2. Remove the battery cover. Removal and Replacement
3. Disconnect the negative battery cable. Removal and Replacement
4. Remove the plug hole plate. Plug Hole Plate Removal/Installation
5. Remove the air cleaner and air hose as a single unit. Service and Repair
6. Disconnect the harness clip as shown in the figure.
7. Remove the PCM harness bracket installation bolt.
8. Disconnect the PCM connector emission harness-side (140-pin). Service and Repair
9. Disconnect the connector as shown in the figure.
10. Disconnect the hose as shown in the figure.
11. Disconnect the following parts connectors.
- Purge solenoid valve
- High pressure fuel pump
- Intake CMP sensor
12. Remove the purge solenoid valve and catch tank and purge solenoid valve bracket as a single unit. Service and Repair
13. Remove the bracket as shown in the figure.
14. Set the wiring harness aside as shown in the figure.
15. Remove in the order indicated in the table.
16. Install in the reverse order of removal.
17. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution
18. Complete the "Fuel Leakage Inspection After High Pressure Fuel Pump Installation". (See Fuel Leakage Inspection After High Pressure Fuel Pump Installation.)
High Pressure Fuel Pipe Removal Note
CAUTION:
- When removing the high pressure fuel pipe, the end of the high pressure fuel pipe may be damaged because the clearance between the high pressure fuel pump and the high pressure fuel pipe is small. Be very careful when handling the end of the high pressure fuel pipe so as not to damage it.
- If the high pressure fuel pump is removed with the high pressure fuel pipe installed, the high pressure fuel pipe and fuel distributor may be damaged because of the excessive force caused by the spring force of the high pressure fuel pump. The high pressure fuel pipe and fuel distributor must be replaced if they are damaged. Always remove the high pressure fuel pipe before removing the high pressure fuel pump.
1. Remove the high pressure fuel pipe.
Rear Housing Removal Note
1. Remove the vacuum pump. Service and Repair
2. Remove the rear housing.
Rear Housing Installation Note
NOTE:
- After applying silicone sealant, install the rear housing within 10 min. and then tighten all bolts within 5 min.
1. Apply silicone sealant to the areas shown in the figure.
Thickness
- 3.0-7.0 mm {0.12-0.27 in}
2. Install the rear housing.
High Pressure Fuel Pump Installation Note
1. Remove the splash shield (RH). Splash Shield Removal/Installation
2. Rotate the crankshaft clockwise approx. 90 degrees from TDC (position shown in figure) of cylinder No.1.
3. Insert the high pressure fuel pump into the rear housing.
4. Press in the high pressure fuel pump until the O-ring cannot be seen.
5. Temporarily tighten the high pressure fuel pump installation bolt on one side until its head contacts the high pressure fuel pump.
6. Tighten the high pressure fuel pump installation bolt which is not tightened in Step 5.
High pressure fuel pump installation bolt tightening torque
- 19-25 Nm {2.0-2.5 kgf-m, 15-18 ft-lbf}
7. Tighten the high pressure fuel pump installation bolt which was tightened in Step 5.
High pressure fuel pump installation bolt tightening torque
- 19-25 Nm {2.0-2.5 kgf-m, 15-18 ft-lbf}
High Pressure Fuel Pipe Installation Note
CAUTION:
- Damage or deformation at the end of the high pressure fuel pipe may cause fuel leakage. When installing the high pressure fuel pipe to the high pressure fuel pump, be very careful while handling the end of the high pressure fuel pipe.
- If parts are exposed to the fuel, their function may be decreased or a fire may occur. Always wipe off the leaked fuel using a clean rag.
- Do not let foreign materials enter into the high pressure fuel pipe.
- The high pressure fuel pipe can be used up to 5 times in a row. When removing/installing the high pressure fuel pipe, always record the number of times in the service records. When removal of the high pressure fuel pipe reaches the 6th time, replace it with a new one.
1. Temporarily tighten the nuts on both ends.
2. Tighten the nuts on both ends.
High pressure fuel pipe tightening torque
- 24-35 Nm {2.5-3.5 kgf-m, 18-25 ft-lbf}
3. Tighten the high pressure fuel pipe bracket installation bolt.
High pressure fuel pipe bracket installation bolt tightening torque
- 9-13 Nm {92-132 kgf-cm, 80-115 in-lbf}
Fuel Leakage Inspection After High Pressure Fuel Pump Installation
1. Verify that the high pressure fuel pump is assembled securely.
2. Verify that there is no fuel leakage around the high pressure fuel pump.