High Pressure Fuel Pump Removal/Installation: Notes

WARNING: This page is about a different variant/trim than selected.

Replacement Part

High pressure fuel pipe Quantity: 1 Location of use: High pressure fuel pump	Seal rubber Quantity: 1 Location of use: High pressure fuel pump	O-ring Quantity: 1 Location of use: High pressure fuel pump
Gasket Quantity: 1 Location of use: Rear housing	-	-

Oil and Chemical Type

Engine oil
Type: Recommended oil

Silicone sealant
Type: TB1217D or equivalent

WARNING:

Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the "FUEL LINE SAFETY PROCEDURE " to prevent the fuel from spraying.
- Fuel may cause irritation if it comes in contact with skin and eyes.
- If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
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.
Connect a ground wire to the oil-resistant fuel hose for draining fuel and the vehicle because the oil resistant fuel hose for draining fuel may become electrically charged.

CAUTION:

Do not damage the sealing surface or the lock part of the fuel pipe.

Courtesy 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.

Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(US)] .)
Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
Remove the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION .)
Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
Remove the turbocharger air outlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
Remove the bolts and set bracket out of the way.

Fig 1: Water Pipe Bracket Bolts With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Remove the bracket.

Fig 2: Bracket Bolt With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Remove the EGR pipe No. 1. (See EGR PIPE REMOVAL/INSTALLATION .)
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.
Install in the reverse order of removal.
Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION .)
Complete the "Fuel Leakage Inspection After High Pressure Fuel Pump Installation". (See FUEL LEAKAGE INSPECTION AFTER HIGH PRESSURE FUEL PUMP INSTALLATION .)

Fig 3: High Pressure Fuel Pump Components With Torque Specification

Courtesy of MAZDA MOTORS CORP.

PART DESCRIPTION

1	Air pipe bracket
2	Protector (See PROTECTOR REMOVAL NOTE .) (See PROTECTOR INSTALLATION NOTE .)
3	Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION .)
4	High pressure fuel pump connector
5	Low fuel pressure sensor/fuel temperature sensor connector
6	High pressure fuel pipe (See HIGH PRESSURE FUEL PIPE REMOVAL NOTE .) (See HIGH PRESSURE FUEL PIPE INSTALLATION NOTE .)
7	High pressure fuel pump (See HIGH PRESSURE FUEL PUMP INSTALLATION NOTE .)
8	Seal rubber
9	O-ring
10	Tension collar
11	Rear housing (See REAR HOUSING REMOVAL NOTE .) (See REAR HOUSING INSTALLATION NOTE .)