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.
• A hot engine can cause severe burns or a fire could start by splashing fuel. After turning off the engine, wait for 5 min or more before performing the servicing.
• Even after performing the fuel line safety procedure, there is still some pressure in the fuel passage, therefore, be careful not to splash fuel when disconnecting. If fuel is splashed, it could cause a fire.

CAUTION:

• Do not disassemble the high pressure fuel pump.
• Do not damage the sealing surface or the lock part of the fuel pipe.

  Courtesy of GENERAL MOTORS COMPANY

• 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". (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
2. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
3. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
5. Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
   • Air hose
   • Air cleaner cover
   • Air cleaner element
   • Air cleaner case
   • Fresh-air duct
6. Remove the clips shown in the figure below.

   Courtesy of GENERAL MOTORS COMPANY

7. Remove the clips shown in the figure below.

   Courtesy of GENERAL MOTORS COMPANY

8. Set the wiring harness protector aside so that it does not interfere with the removal work. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
9. Remove the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
10. Remove the bolt shown in the figure below. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)

    Courtesy of GENERAL MOTORS COMPANY

11. Disconnect the upper radiator hose from the water pipe side.
12. Remove the clip shown in the figure below and disconnect the lower radiator hose on the thermostat side.

    Courtesy of GENERAL MOTORS COMPANY

13. Set the lower radiator hose aside so that it does not interfere with the servicing.
14. Disconnect the following parts connectors.
    • High pressure fuel pump
    • Low fuel pressure sensor/fuel temperature sensor connector
    • Intake CMP sensor
    • ECT sensor No. 1
15. 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.
16. Install in the reverse order of removal.
17. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
18. Complete the "Fuel Leakage Inspection After High Pressure Fuel Pump Installation". (See Fuel Leakage Inspection After High Pressure Fuel Pump Installation .)

Fig 1: High Pressure Fuel Pump Components Location With Torque Specifications

Courtesy of GENERAL MOTORS COMPANY

COMPONENT OPERATIONS

Component no.	Refer to
1	Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION)] .)
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 .)