4.
Remove the high pressure pipe (A) connecting high pressure fuel pump and common rail.
Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,600 bar)
Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Always pay attention to safety precaution.
Ensure the absolute cleanliness.
It is not recommended to remove the injectors without any notice.
Turn ignition switch off.
Disconnect the negative battery (-) terminal and wait for about 30 seconds.
Remove the intake manifold. (Refer to the group "EM" in this WORKSHOP MANUAL).
Remove the high pressure pipe (A) connecting high pressure fuel pump and common rail.
Disconnect the fuel pressure regulator valve connector (B).
Remove the oil gage guide.
Disconnect the feed tube (A) and the return tube (B).
Unscrew the three high pressure fuel pump mounting bolts (C).
Remove the drive belt (Refer to the group "EM" in this WORKSHOP MANUAL).
Turn the crankshaft pulley and align its groove with timing mark "T" of the timing chain cover.
(NO.1 cylinder compression TDC position.)
Remove the idler (A) and the timing chain cover plug (B).
Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
Install the high pressure fuel pump sprocket stopper (A) (SST No.: 09331-2A000) with rotating it clockwise.
Install the high pressure fuel pump remover (SST No.:09331-2A000) (A) with three mounting bolts (B).
Fix the high pressure fuel pump remover (SST No.:09331-2A000) (A) and sprocket stopper (C) with two fixing bolts (D).
Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:09331-2A000) (A) clockwise till the high pressure fuel pump is pushed out.
Install the high pressure fuel pump according to the reverse order of "REMOVAL" procedure.
When installing the high pressure pipe, apply the specified tightening torques to the flange nuts of the high pressure pipe side and the common rail side with SST (Refer to below table).
Item | Dimension | SST No. |
Flange Nut (HP Pump Side) | 14 mm (0.551 in) | 09314-27110 |
Flange Nut (Common Rail Side) | 17 mm (0.669 in) | 09314-27120 |
· High pressure fuel pump installation bolts: 14.7 ~ 19.6 N·m (1.5 ~ 2.0 kgf·m, 10.9 ~ 14.5 lbf·ft)
· High pressure pipe flange nuts (Common Rail ↔ High Pressure Fuel Pump):
24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
