High Pressure Fuel Pump Removal/Installation

HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

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 the "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.
- Do not scratch or damage the fuel sealing surface of the high and low fuel ports.
- When removing the high pressure fuel pipe, secure the joint (pump side) so that it does not rotate, and loosen the screw (pipe side).

NOTE:
- If the high pressure fuel pump is removed, replace the O-ring with a new one.

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. Disconnect the spill valve control solenoid valve connector.

5. Disconnect the quick release connector on the high pressure fuel pump. Quick Release Connector Removal/Installation






6. Remove the battery and battery tray. Removal and Replacement

7. Remove the air duct. (See Service and Repair)

WARNING:
- If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes. When removing the high pressure line pipe, always tighten the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench. If the high pressure fuel pump joint nut has rotated, replace the high pressure fuel pump with a new one.

8. Disconnect the high pressure line pipe of the high pressure fuel pump.






a. Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.

b. Loosen the high pressure line pipe installation nut.

9. Drain the engine coolant. Service and Repair

10. Loosen the water outlet case installation bolts securing the high pressure line pipe.

11. Remove the high pressure fuel pump and tension collar.






NOTE:
- When high pressure fuel pump cover removal/installation, it does according to the work of procedure 12-14.

12. Remove the drain plug and drain the engine oil accumulated in the high-pressure fuel pump cover.
NOTE:
- 20-30 ml {20-30 cc, 1.3-1.8 cu in} of engine oil will drain out when the plug is removed so put a cloth under the drain plug beforehand.





13. Remove the high pressure fuel pump cover.






14. Install the high pressure fuel pump cover.






a. Apply the silicone sealant to the contact surfaces of the camshaft cap and cylinder head.

Diameter
- 5 mm {0.2 in}

b. Tighten the high pressure fuel pump cover bolts.

Tightening torque
- 17-23 Nm {1.8-2.3 kgf-m, 13-16 ft-lbf}

c. Apply the silicone sealant to the drain plug.

d. Tighten the drain plug.

Tightening torque
- 12-17 Nm {123-173 kgf-cm, 107-150 in-lbf}

CAUTION:
- If the high pressure fuel pump installation bolts are tightened with the high pressure fuel pump tilted, the high pressure fuel pump may not operate correctly. Tighten the high pressure fuel pump installation bolts in a few passes with equal torque.
- When installing the high pressure fuel pump, be careful with the end of the high pressure line pipe so that the end of the pipe does not get scratched or damaged when working in the narrow space (clearance) between the high pressure line pipe and high pressure fuel pump.






15. Tighten the bolts on the high pressure fuel pump.

Tightening torque
- 9-11 Nm {92-112 kgf-cm, 80-97 in-lbf}

CAUTION:
- Any damage or deformation to the tip of the high pressure line pipe could cause fuel leakage. To prevent damage, handle the end of the high pressure line pipe with care when installing the high pressure fuel pump.

16. Verify that the end of the high pressure line pipe is free of damage or deformation.

- If there is a malfunction, replace the high pressure line pipe.

17. Assemble the high pressure line pipe with care so that the end does not get damaged.






a. Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.

b. Tighten the high pressure line pipe installation nut.

Tightening torque
- 24-35 Nm {2.5-3.5 kgf-m, 18-25 ft-lbf}

18. Tighten the water outlet case installation bolts.

Tightening torque
- 8-11 Nm {82-112 kgf-cm, 71-97 in-lbf}

19. Connect the quick release connector. Quick Release Connector Removal/Installation

20. Complete the "Fuel Leakage Inspection After High Pressure Fuel Pump Installation". (See Fuel Leakage Inspection After High Pressure Fuel Pump Installation.)

21. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution

Fuel Leakage Inspection After High Pressure Fuel Pump Installation

1. Verify that the high pressure fuel pump is assembled securely.

2. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.

3. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the high pressure fuel pump.