Removal and installation of the high pressure fuel pump
1. Nut of fastening of a clip.
2. Pressure fuel line.
3. Clamp.
4. Bracket.
5. Fuel return line.
6. Main fuel hose.
7. High pressure fuel pump.
8. Spacer.
Note.
: replace the part with a new one after each removal.
: apply oil.
Attention.
- Leaks in the fuel lines of a pressurized system are dangerous. Fuel can ignite and cause equipment damage, serious injury or even death. In addition, fuel can get on the skin and in the eyes of a person. To prevent this, it is imperative to perform a pressure relief procedure in the power system.
- A person carrying static electricity can cause a fire or explosion that could result in death or serious injury. Before working on the fuel system, you must remove the static charge from yourself by touching the car body.
- If fuel comes into contact with engine parts, it may cause these components to malfunction or cause a fire. Be sure to clean up any spilled fuel with a clean rag.
- Do not allow foreign material to enter the high pressure fuel line. To do this, always tighten the high-pressure fuel line connections to the specified tightening torque.
- To prevent the occurrence of fuel leaks, the procedures described in this manual must be strictly followed.
Note. If the high pressure fuel pump is replaced, the fuel pump initialization procedure must be performed.
Removing the high pressure fuel pump
1. Disconnect the negative battery terminal.
2. Complete the power system maintenance preparation procedure.
3. Remove the decorative engine cover.
4. Remove the air filter.
5. Remove the battery from the shelf.
6. Remove air and ventilation hoses, turbocharger inlet hose and electric heater.
7. Move aside the turbocharger outlet duct as shown in the figure.
8. Drain coolant.
9. Remove the cooling system pipe to the side, as shown in the figure.
10. Disconnect the hose clamps shown in the figure.
11. Disconnect the electrical wiring clamp shown in the figure.
12. Loosen the fuel pressure line clamp nut.
13. Loosen the union nut and remove the fuel pump high pressure fuel line as shown.
14. Remove the fuel line clamp.
15. To turn away bolts of fastening and to remove an arm of the fuel pump of a high pressure.
16. Disconnect return and main fuel hoses.
17. Unscrew the mounting bolts and remove the fuel pump with the intake valve in one assembly.
18. Remove the intake valve from the high pressure fuel pump.
High pressure fuel pump installation
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 illustrations.
Fuel pump side
Bottom case side
Install the fuel return hose as shown in the following illustrations.
Fuel pump side
Bottom case side
Perform the bleed procedure for the fuel lines.
Attention. If the high pressure fuel pump is found to be defective, send it in for repair by contacting an authorized DENSO Ltd. representative. Do not disassemble the high pressure fuel pump yourself.