Removal and installation of the high pressure fuel pump
1. Quick connector.
2. High pressure fuel line.
3. High pressure fuel pump cover.
4. High pressure fuel pump.
5. Rubber seal.
6. O-ring of circular cross-section.
7. Tension sleeve.
8. Rear case.
Note.
: replace the part with a new one after each removal.
: where to apply the sealant.
: 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.
- Do not disassemble the high pressure fuel pump.
- Be careful not to damage the sealing surfaces of the obturator of the fuel lines.
- A damaged or deformed edge of the high pressure fuel line can cause fuel leaks.
- Disconnecting/connecting quick connectors without first cleaning them from the outside can cause damage to the fuel lines and quick connectors. Be sure to clean the quick connector area before disconnecting/connecting with a cloth or soft brush. Make sure there is no foreign material near the quick connector.
Removing the high pressure fuel pump
1. Relieve the pressure in the fuel system (see relevant section above).
2. Disconnect the negative battery terminal.
3. Remove the decorative engine cover.
4. Remove the air filter with air hose in one piece.
5. Disconnect the wiring clamps shown in the figure.
6. Disconnect the hoses shown in the figure.
7. Disconnect the following connectors:
- Solenoid purge valve.
- High pressure fuel pump.
- Intake camshaft position sensor.
8. Remove solenoid purge valve with trap and bracket in one assembly.
9. Disconnect the quick connector by prying on the retainer with a flathead screwdriver or similar tool.
Attention.
- When removing the high pressure fuel line, the edge of the fuel line may be damaged due to the small clearance between the high pressure fuel pump and the fuel line. Be extremely careful not to damage the end of the high pressure fuel line.
- If the high pressure fuel pump is removed with the high pressure fuel line installed, the high pressure fuel line and fuel rail may be damaged by the spring action of the high pressure fuel pump. If damaged, the high pressure fuel line and fuel rail must be replaced with new ones. Be sure to remove the high pressure fuel line before removing the high pressure fuel pump.
10. Remove the high pressure fuel line.
11. Remove the high pressure fuel pump cover.
12. To turn away bolts of fastening and to remove the fuel pump of a high pressure.
13. Remove the rubber seal, O-ring and tensioner from the high pressure fuel pump.
14. Remove the vacuum pump.
15. To turn away bolts of fastening and to remove the back case from the engine.
High pressure fuel pump installation
Installation is carried out in the reverse order of removal, taking into account the following:
Installing the back case
Apply silicone sealant to the indicated areas of the engine.
Note. After applying sealant, install rear housing within 10 minutes and tighten all bolts within 5 minutes of applying sealant.
Install the rear housing to the engine.
High pressure fuel pump installation
Rotate the crankshaft approximately 90°from the TDC mark on the No. 1 cylinder.
Insert the high pressure fuel pump into the rear housing.
Press in the high pressure fuel pump until the O-ring is hidden.
Install the mounting bolt on one side of the high pressure fuel pump until its head touches the pump body.
Screw in and tighten the second high pressure fuel pump bolt to 19-25 Nm.
Tighten the first high pressure fuel pump bolt to 19-25 Nm.
High pressure fuel line installation
Attention.
- A damaged or deformed edge of the high pressure fuel line can cause fuel leaks.
- 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.
- The high pressure fuel line can be removed and installed up to five times. Whenever removing/installing the high pressure fuel line, it is imperative to make appropriate marks in the service book. After the fifth reinstallation of the high pressure fuel line, it must be replaced with a new one.
Install nuts on both sides of the fuel line.
Install the high pressure fuel line bracket bolt.
Tighten the nuts on both sides of the high pressure fuel line to 24-35 Nm.
Tighten the high pressure fuel line bracket bolt to 9-13 Nm.
Checking for Fuel Leaks After Installing the High Pressure Fuel Pump
Carry out the necessary operations after servicing the power system.
Make sure the high pressure fuel pump is securely installed.
Check for fuel leaks around the high pressure fuel pump.