High Pressure Side Fuel Pump Removal

Disconnect the cable from the negative (-) battery terminal.

NOTICE:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

Disconnect the fuel pump connector.

Connect the cable to the negative (-) battery terminal.

Start the engine. After the engine has stopped on its own, turn the engine switch off.

HINT:

DTC P0171/P0172 (system too lean) may be set.

Crank the engine again, then check that the engine does not start.

Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.

Connect the fuel pump connector.

Remove the 7 clips and duct seal.

Using a clip remover, remove the 3 clips.

Remove the 10 screws and under cover.

Remove the radiator cap and reservoir cap.

Loosen the radiator drain cock plug and 2 cylinder block drain cock plugs. Then drain the coolant.

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Loosen the nut and remove the 2 clips and side cover.

Remove the 2 nuts and V-bank cover.

Disconnect the ventilation hose from the cylinder head.

Disconnect the MAF meter connector.

Disconnect the clamp from the air cleaner.

Disconnect the VSV (for EVAP).

Disconnect the 4 clamps.

Remove the hose clamp and air cleaner cap with air cleaner hose.

Disconnect the 2 water by-pass hoses from the throttle body.

Disconnect the hose from the water hose joint.

Remove the 3 clips and engine rear cover.

Remove the fuel pipe clamp.

Pinch and pull the fuel tube's connector to disconnect it from the fuel main pipe.

NOTICE:

1. Check for foreign matter in the fuel tube around the fuel tube's connector. Clean it if necessary. Foreign matter can affect the O-ring's ability to seal the connector and fuel main pipe.
   
2. Do not use any tools to separate the connector and pipe.
   
3. Do not forcefully bend or twist the hose.
   
4. Keep the connector and pipe free from foreign matter.
   
5. If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
   


6. Put the connector in a plastic bag to prevent damage and contamination.
   

Disconnect the hose from the surge tank.

Disconnect the ventilation hose from the ventilation valve.

Disconnect the throttle motor connector.

Disconnect the IACV connector.

Disconnect the wire harness clamp from the surge tank.

Remove the 2 bolts and intake manifold stay.

Disconnect the 2 wire harness clamps from the surge tank stays.

Remove the 4 bolts and 2 surge tank stays.

Remove the bolt and disconnect the water hose joint.

Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.

HINT:

Cover the intake manifold port to prevent foreign matter from entering it.

Disconnect the DC motor connector for the SCV.

Disconnect the SCV position sensor connector.

Remove the 4 bolts, 4 nuts, intake manifold and gasket.

HINT:

Cover the cylinder head intake port to prevent foreign matter from entering it.

Disconnect the fuel pipe hose.

Remove the 2 bolts and fuel pipe.

Remove the fuel pulsation damper and 2 gaskets, and disconnect the fuel main tube from the fuel pump.

Disconnect the fuel high pressure side fuel pump connector.

Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.

NOTICE:

1. There must be absolutely no free play in the union on the fuel pump side.
   
2. If the union on the fuel pump side has free play, replace the fuel pump.
   

Remove the 2 bolts on the delivery pipe side.

NOTICE:

1. Do not remove the fuel pipe from the delivery pipe. Only remove the 2 bolts.
   
2. If the No. 2 fuel pipe is accidentally removed, replace its O-ring, No. 1 backup ring and No. 2 backup ring.
   

Disconnect the fuel hose.

Remove the 2 nuts, fuel pump and fuel pump insulator.