Repair Procedures: Replacement

Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ".)
Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
Disconnect the fuel pressure control valve connector (B) and the fuel feed tube quick-connector (A).

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NOTE: Open the clamp cover (B) before disconnecting the quick connector. (If the clip is applied)

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CAUTION:
- When removing the quick-connector with the clip removing tool (A), be careful not to damage the plastic clip (B).
- If the clip is damaged, fuel line leak can occur due to a poor connection.
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Remove the surge tank.
(Refer to Engine Mechanical System - "SURGE TANK ")
Remove the high pressure fuel pipe.
(Refer to Fuel Delivery System - "FUEL LINE )
Remove the installation bolts (A), and then remove the high pressure fuel pump from the cylinder head assembly.

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Install in the reverse order of removal.

WARNING:

Listen for a 'click' sound to confirm that the low pressure fuel hose quick-connector (A) is correctly connected to the high pressure fuel pump.
Double check that the low pressure fuel hose is correctly connected to the high pressure fuel pump by pulling it after connecting.
Be sure to install the high pressure fuel pipe (B) to the specified torque.
As fuel leakage may cause fire, thoroughly check for leakage on all fuel line connections during engine start.

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NOTE:

Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may get broken due to tension of the pump spring.
Do not reuse the bolts.
Do not reuse the high pressure fuel pipes.
When tightening the installation bolts of the high pressure fuel pump, pretighten the bolts by hand and then tighten them in turns in small steps (0.5 turns).
Install the component to the specified torque.
First, pretighten the fasteners by hand until they cannot be fastened anymore, and then fully tighten them to the specified torque using a torque wrench.
If the bolts or nuts are not tightened in a straight line with the mating bolt holes or fittings, fuel leakage may result due to broken threads.
Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

NOTE:

Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove on the location where the protrusion (C) is installed.

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