High pressure fuel pump for engines manufactured since 1999 (Mitsubishi Space Star)

Contents: Removal ⤓ Installation ⤓ Installing the support rings (A and…⤓

Removal

Reduce the pressure in the fuel system.

Warning: Before disconnecting the fuel lines, relieve the pressure in the fuel system, otherwise pressurized fuel will leak out of the fuel system.

Remove the bolts and remove the engine cover.
Remove the air filter.
Removal the fuel pressure regulator.
Disconnect the wiring harness connector from the fuel pressure sensor and remove the wiring harness clamp mounting bolt (Fig. 6.33).

Fig. 6.33. High-pressure fuel pump of the engine since 1999: 1 - wiring harness connector; 2 - clamp (fastening fuel lines); 3 - fuel supply pipe; 4 - fuel return hose; 5 - low pressure fuel pipe; 6 - fuel return pipe; 7 - fuel pressure regulator (high pressure side); 8 - flange; 9 - pressure/fuel sensor; 10 - sealing ring; 11 - Support ring; 12 - fuel return hose; 13 - fuel hose; 14 - fuel pipe; 15 - high pressure fuel pump; 16 - fuel return pipe; 17 - support ring A; 18 - sealing ring; 19 - support ring B; 20 - high pressure fuel pump housing

Loosen the clamps and disconnect the fuel return hoses.
Remove the bolts and low pressure fuel line
Remove the bolts and fuel return pipe.
Remove the bolts and fuel pressure regulator (high pressure side).
If the fuel pressure sensor is to be reinstalled, before removing the flange, mark and mark the relative position of the flange and sensor (Fig. 6.34). Unscrew the bolts and remove the fuel pressure sensor mounting flange.

Fig. 6.34. Location of marks determining the relative position of the flange and the fuel pressure sensor

Note: When tightening the mounting bolts, the flange will be deformed, which will keep the sealing condition and the installation position of the sensor in good condition. Therefore, it is necessary to apply installation marks to install the flange and sensor in the original position. When replacing the fuel pressure sensor, it is also necessary to replace the flange.

Remove the fuel pressure sensor.
Loosen the clamps and disconnect the fuel return hoses.
Remove the bolts and low pressure fuel line
Remove the bolts and fuel return pipe.
Remove the bolts and fuel pressure regulator (high pressure side).
Unscrew the bolts and remove the fuel pressure sensor mounting flange.
Remove the fuel pressure sensor.
Removal the high pressure fuel pump
Remove the throttle assembly.
Remove the bolts and clamps securing the fuel lines.
Remove the bolts and fuel supply pipe.
Loosen the clamp and disconnect the fuel return hose from the pipe.
Remove the bolts and disconnect the fuel hose from the high pressure fuel pump.
Remove the bolts and disconnect the fuel line from the high pressure fuel pump.
Remove the bolts and high pressure fuel pump.
Removal the high pressure fuel pump housing.
Remove the bolts and fuel pressure regulator (high pressure side).
Remove the bolts and high pressure fuel pump.
Remove the bolts and disconnect the fuel return line.
Remove the bolts and remove the high pressure fuel pump housing.

Installation

Installation is carried out in the reverse order of removal, taking into account the following.
Installing the high pressure fuel pump housing
Set the piston of the 1st cylinder to TDC in the compression stroke.
Align the timing marks on the high-pressure fuel pump housing and coupling, then install the high-pressure fuel pump housing onto the engine (Fig. 6.35).

Fig. 6.35. Alignment of the installation (1 marks on the fuel pump housing) high pressure and coupling

Warning: Before installation, be sure to check the presence of the sealing ring in the high-pressure fuel pump housing and do not drop the ring when installing the housing.

Installing the support rings (A and B) of the sealing ring

Install the support rings and sealing ring as shown in Figure 6.36.

Fig. 6.36. Installation position of support rings and sealing ring

Warnings

1. Install the support ring B so that the beveled surface of the ring is located on the side opposite the sealing ring.

2. Make sure that the support ring A is installed correctly (the outer diameter of the support ring A is 14.8 mm). Do not confuse it with the support ring of the pressure sensor.

Installing fuel supply and return pipes and low pressure fuel pipes

When installing the fuel pipes, lubricate the O-ring with a small amount of clean engine oil (Fig. 6.37).

Fig. 6.37. Installing the high pressure fuel hose: 1 - place of lubrication with engine oil; 2 - fuel pipe; 3 - O-ring gasket

Warning: Do not allow oil to enter the fuel pump, fuel pressure regulator or fuel line.

Installing a high pressure fuel pump

To tighten the fuel pump mounting bolts, use a torque wrench that provides a tightening accuracy of 0.5 N·m. Tighten the fuel pump mounting bolts in the sequence shown in Figure 6.38 as follows.

1. Tighten the bolts to 5 Nm.
2. Tighten the bolts to a torque of 17 N·m. The difference in tightening torque between the four bolts must not exceed 2 N·m.

Fig. 6.38. Fuel pump mounting bolt tightening sequence

Installing the fuel hose

When installing the fuel hose, lubricate the O-ring with a small amount of clean engine oil. Do not allow oil to enter the fuel pump.
While slightly turning the flange of the fuel hose to the right and left, carefully insert it into the fuel pump so as not to damage the O-ring seal. After installation, check that the hose rotates smoothly in the fuel pump.
If the hose flange jams when turning, damage to the O-ring gasket may occur. Disconnect the flange (complete with hose) from the fuel pump and check the gasket for any damage, then insert it back and check for smooth turning.

Installing the fuel pressure sensor support ring

Install the support and sealing rings on the fuel pressure sensor as shown in Figure 6.39.

Fig. 6.39. Installation position of the support and sealing rings

Warning: Make sure that the support ring (outer diameter of support ring A is 15.1 mm) is installed correctly. Do not confuse it with the support ring of the injector, fuel supply pipe and fuel return pipe.

Installing the fuel pressure sensor and flange

Lubricate the fuel pressure sensor sealing ring with engine oil. Do not allow oil to enter the fuel pressure regulator.
Align the marks made before removing the sensor and install the fuel pressure sensor and flange onto the fuel pressure regulator.