High Pressure Fuel Pump Removal/Installation: Notes

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 dose 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.

Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Disconnect the negative battery cable.
Remove the charge air cooler duct.
Disconnect the spill valve control solenoid valve connector.
Disconnect the quick release connector on the high pressure fuel pump. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] .)
Remove the air duct. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
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.
Disconnect the high pressure line pipe of the high pressure fuel pump.

Fig 1: Disconnecting High Pressure Line Pipe Of High Pressure Fuel Pump
Courtesy of MAZDA MOTORS CORP.
1. Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
2. Loosen the high pressure line pipe installation nut.
Drain engine coolant. (See ENGINE COOLANT REPLACEMENT .)
Loosen the water outlet case installation bolts securing the high pressure line pipe.
Remove the following part:
- High pressure fuel pump
- Tension collar
Perform the following procedure when removing the high pressure fuel pump cover.

Fig 2: Locating High Pressure Fuel Pump And Tension Collar With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
1. 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.
    
    Fig 3: Removing Drain Plug
    Courtesy of MAZDA MOTORS CORP.
2. Remove the high pressure fuel pump cover.
  
  Fig 4: Exploded View Of High Pressure Fuel Pump Cover
  Courtesy of MAZDA MOTORS CORP.
3. Install the high pressure fuel pump cover.
  1. Apply the silicone sealant to the contact surfaces of the camshaft cap and cylinder head.
    Diameter
    
    5 mm {0.2 in}
  2. Tighten the high pressure fuel pump cover bolts.
    
    Fig 5: Tightening High Pressure Fuel Pump Cover Bolts With Torque Specifications
    Courtesy of MAZDA MOTORS CORP.
    
    Tightening torque
    
    17-23 N.m {1.8-2.3 kgf.m, 13-16 ft.lbf}
  3. Apply the silicone sealant to the drain plug.
  4. Tighten the drain plug.
    Tightening torque
    
    11.8-17.6 N.m {121-179 kgf.cm, 105-155 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.
Tighten the bolts on the high pressure fuel pump.
Tightening torque

8.5-11.5 N.m {87-117 kgf.cm, 76-101 in.lbf}
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 installing 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.
Assemble the high pressure line pipe.

Fig 6: Installing High Pressure Line Pipe
Courtesy of MAZDA MOTORS CORP.
1. Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
2. Tighten the high pressure line pipe installation nut.
  Tightening torque
  
  23.5-35.5 N.m {2.40-3.59 kgf.m, 17.4-26.0 ft.lbf}
Tighten the water outlet case installation bolts.
Tightening torque

8-11.5 N.m {82-117 kgf.cm, 71-101 in.lbf}
Install the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)