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 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.

Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION ).
Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
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 ).

Fig 1: Identifying Quick Release Connector
Courtesy of MAZDA MOTORS CORP.
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 2: Loosening High Pressure Line Pipe Installation Nut
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 the engine coolant. (See ENGINE COOLANT REPLACEMENT ).
Loosen the water outlet case installation bolts securing the high pressure line pipe.
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.
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: High Pressure Fuel Pump, Tension Collar And Mounting Bolts With Torque Specifications
  Courtesy of MAZDA MOTORS CORP.
  
  Fig 4: Removing Drain Plug
  Courtesy of MAZDA MOTORS CORP.
Remove the high pressure fuel pump cover.

Fig 5: Identifying High Pressure Fuel Pump Cover With Mounting Bolts
Courtesy of MAZDA MOTORS CORP.
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.
  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

12-17 N.m {123-173 kgf.cm, 107-150 in.lbf}

Fig 6: Applying Silicone Sealant To Contact Surfaces Of Camshaft Cap And Cylinder Head With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
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.
Tighten the bolts on the high pressure fuel pump.
Tightening torque

9-11 N.m {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.
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.
  
  Fig 7: Identifying Clearance Between High Pressure Line Pipe And High Pressure Fuel Pump
  Courtesy of MAZDA MOTORS CORP.
Assemble the high pressure line pipe with care so that the end does not get damaged.

Fig 8: Tightening High Pressure Line Pipe Installation Nut
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

24-35 N.m {2.5-3.5 kgf.m, 18-25 ft.lbf}
Tighten the water outlet case installation bolts.
Tightening torque

8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
Connect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION ).
Complete the "Fuel Leakage Inspection After High Pressure Fuel Pump Installation". (See FUEL LEAKAGE INSPECTION AFTER HIGH PRESSURE FUEL PUMP INSTALLATION ).
Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION ).