High Pressure Fuel Pump Removal and Installation (1.5 L Engine): Removal

WARNING: 

Flammable - Keep Fire Away

NOTE:  Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line.

1. Fuel Pressure - Relieve
2. Intake Air Resonator - Remove
3. Throttle Body - Move

   NOTE: 

   • Do not disconnect the water bypass hoses.
   • Do not bend the water bypass hoses excessively.
4. Intake Manifold Bracket - Remove

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5. Intake Manifold - Remove
6. High Pressure Fuel Pump Cover - Remove

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   1. Disconnect the quick-connect fitting (A). 2. Remove the high pressure fuel pump cover (B).

7. Fuel Joint Pipe - Remove

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   1. Remove the fuel joint pipe (A).

8. High Pressure Fuel Pump - Remove

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   1. Disconnect the connector (A). 2. Loosen the bolts (B) alternately, and remove the high pressure fuel pump (C) with the O-ring (D), and the roller (E).

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   3. Remove the fuel feed pipe (A) with the sealing washers (B) from the high pressure fuel pump (C).

9. High Pressure Fuel Pump Cam - Check

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   1. Rotate the crankshaft and check the high pressure fuel pump cam (A) for pits, scores, or excessive wear. If needed, replace the intake camshaft .

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   2. Set the No. 1 piston at bottom dead center (BDC). 3. Install the roller (A) to the high pressure fuel pump cam. 4. Set the gauge (B) on the roller and hold it, then set the dial to zero. 5. Rotate the crankshaft 720 deg. and measure the four cam lobes height. If the cam lobes are excessive worn, replace the intake camshaft .NOTE:  The high pressure fuel pump cam has four cam lobes.Cam Lobe Height Standard (New): 0.146 in (3.7 mm)