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High Pressure Fuel Pump Removal/Installation: Notes

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 "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 damage the sealing surface or the lock part of the fuel pipe.
    Fig 1: Identifying Fuel Pipe And Sealing Surface
    G10960059Courtesy of MAZDA MOTORS CORP.
  • Damage or deformation to the end of the high pressure line pipe may cause fuel leakage.
  • Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.
  1. Complete the "BEFORE SERVICE PRECAUTION". (Refer to BEFORE SERVICE PRECAUTION .)
  2. Disconnect the negative battery cable. (Refer to NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION .)
  3. Remove the plug hole plate. (Refer to PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  4. Remove the air cleaner and air hose as a single unit. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  5. Disconnect the harness clip as shown in the figure.
    Fig 2: Disconnecting Harness Clip
    G10960060Courtesy of MAZDA MOTORS CORP.
  6. Disconnect the hoses as shown in the figure.
    Fig 3: Disconnecting Vacuum And Evaporative Hoses
    G10960061Courtesy of MAZDA MOTORS CORP.
  7. Disconnect the following parts connectors.
    • Purge solenoid valve
    • High pressure fuel pump
    • Intake CMP sensor
  8. Remove the purge solenoid valve and catch tank and purge solenoid valve bracket as a single unit. (Refer to PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  9. Remove in the order indicated in the table.
    NOTE:
    • Only when the high pressure fuel pump is removed, the rear housing does not have to be removed.
  10. Install in the reverse order of removal.
  11. Complete the "AFTER SERVICE PRECAUTION". (Refer to AFTER SERVICE PRECAUTION .)
  12. Complete the "Fuel Leakage Inspection After High Pressure Fuel Pump Installation". (Refer to FUEL LEAKAGE INSPECTION AFTER HIGH PRESSURE FUEL PUMP INSTALLATION .)
    Fig 4: High Pressure Fuel Pipe Components With Torque Specifications
    G10960062Courtesy of MAZDA MOTORS CORP.
    COMPONENT DESCRIPTION

    1 Quick release connector
    (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5] .)
    2 High pressure fuel pipe
    (See High Pressure Fuel Pipe Removal Note .)
    (See High Pressure Fuel Pipe Installation Note .)
    3 High pressure fuel pump
    (See High Pressure Fuel Pump Installation Note .)
    4 Seal rubber
    5 O-ring
    6 Tension collar
    7 Rear housing
    (See Rear Housing Removal Note .)
    (See Rear Housing Installation Note .)
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