Removal and installation the high pressure fuel pump (Mazda CX-5KE)

Removal and installation the high pressure fuel pump

Note.

: replace the part with a new one after each removal.

: apply oil.

Attention.

• Leaks in fuel lines in a pressurized system are dangerous. Fuel can ignite and cause equipment damage, serious injury, or even death. Fuel can also come into contact with human skin and eyes. To prevent this, it is essential to perform a pressure relief procedure in the fuel system.
• A person carrying a static charge can cause a fire or explosion, which could result in death or serious injury. Before working on the fuel system, you must discharge static electricity by touching the vehicle body.
• If fuel gets on engine parts, it may cause damage to those components or cause a fire. Be sure to wipe up any spilled fuel with a clean rag.
• Prevent foreign materials from entering the high-pressure fuel line. To do this, be sure to tighten the high-pressure fuel line connections to the specified tightening torque.
• To prevent fuel leaks, it is important to strictly follow the procedures described in this manual.

Note: If the high pressure fuel pump is replaced, the fuel pump initialization procedure must be performed.

Removal the high pressure fuel pump

1. Disconnect the negative battery terminal.

2. Perform the procedure for preparing for servicing the power supply system.

3. Remove the decorative engine cover.

4. Remove the air filter.

5. Remove the battery from the shelf.

6. Remove the air and ventilation hoses, turbocharger inlet hose and electric heater.

7. Move the turbocharger air outlet duct to the side as shown in the figure.



8. Drain the coolant.

9. Move the cooling system hose to the side as shown in the figure.



10. Disconnect the hose clamps shown in the figure.



11. Disconnect the wiring clamp shown in the figure.





12. Loosen the fuel pressure line clamp nut.

13. Loosen the union nut and remove the high pressure fuel line of the fuel pump, as shown in the figure.



14. Remove the fuel line clamp.

15. Loosen the mounting bolts and remove the high-pressure fuel pump bracket.

16. Disconnect the return and main fuel hoses.

17. Loosen the mounting bolts and remove the fuel pump with the intake valve as one unit.

18. Remove the intake valve from the high pressure fuel pump.

Installing a high pressure fuel pump

Installation is carried out in the reverse order of removal, taking into account the following:

Install the main fuel hose as shown in the following figures.





Install the fuel return hose as shown in the following figures.







Perform the procedure for removing air from the fuel lines.

Caution: If a fault is detected in the high-pressure fuel pump, it must be sent for repair by an authorized representative of DENSO Ltd. Do not disassemble the high-pressure fuel pump yourself.