Originally Posted by
MPS2NV
Tools use to carry out internal upgrade are prob not in you home DIY kit, you will need torx socket (think it was size 6, never looked), 19mm spanner, security type torx bit , deep socket (from memory) also 19mm single hex, small pick or flat screw driver and bench vice ( with some means of protection to avoid external damage to the pump body)
As I have access to workshop equipment I dissmantled the whole pump cleaning and drying it completely before assembling. It may not be needed but it would be poor not to do so! If you are going to attempt to do this job and your not mecahnically minded pay attention to part orientation as inside the pump is more involved then what you might think given its size. Make sure you have the above equipment before you touch the pump!
As Sams car has aftermarket TMIC I was able to gain access to HPFP easy without need to remove other parts, covers etc... Make sure the car is cool and hasn't been running, best to be safe when working on your pride and joy! Expect fuel pressure when disconnecting the the fuel lines from the pump! watch your eyes!
Step 1, Turn off ignition and remove key! Disconnect the battery also. Remove engine covers as required to access HPFP ( I managed to have enough access to remove pump body!) disconnect the wire to sensor on top of the HPFP
Step 2, disconnect the fuel lines from the HPFP expect fuel to spray your in your eyes , be gentle with the yellow and blue clip, the yellow clip will click out easy but dont be to rough on the blue clip! the position of the blue clip is critical on re installation! Remove the high pressure line nut from the bottom of the HPFP 19mm spanner ( I advise packing a rag under the pump to prevent the nut sliding down the fuel line into the abiss lol)
Step 3, There is 3 torx bolts holding the HPFP into its position, undo each of these bolts a little at a time to let the pump come out evenly from its housing ( depending on the engine position the cam lobe may have full lift on the pump, this may be an issue on installation, if that is the case turn engine clock wise from crank pulley to allow pump be refitted easier, you will work it out!) The pump should now come out! make sure the bucket doesn't fall out of the hole where the pump was, cover the hole with a clean rag to make sure shit doesn't go in it!
Step 4, I suggest doing this part in a clean tidy place! The factory spring and piston will come out easy, gently hold the spring and pull it, the spring and shaft should now be in your hand! You will see a shiney nut where the spring and shaft came from, you will need to hold the pump body in the vice (with timbers or rags, dont crush it ethier!) the nut is tight! undo the nut and pay attention to the piston inside! the ends are different sizes! if you keep the parts in correct orientation it will give you more confidence that you are doing it right!
Step 5, With your torx bits remove the 2 screws and plate, inside are some discs and rings, dont **** this up. make sure they go in the same way they came out. This allows you so clean the whole hole HPFP body, it will have a fine coating of wear debree in it. Clean it and the parts well, dry it well! then install the disc's and plate. This step is optional but its best time to do it!
Step 6, Its time to install the new internals, you will notice that the new piston and shaft can only be fitted before the retaing nut can go back into the HPFP body, ensure the new piston is in the correct way! use a slight smear of clean oil on the parts, gently push the shaft through the nut, there is a seal in there that you dont wont to damage. The spring and new collets and retaining ring can go on once the piston, shaft and retaining nut have been installed. The new shaft will not pull out like the factory one did but this step is also important to avoid a pump failure! Pull the shaft out as far as it will go, place the spring over the shaft followed by the retaining ring and 2 little collets. Pay attention to the seating position of the collets, retainer and spring. gently push the shaft inwards and check that the collets are seated correctly! The HPFP is now ready to be refitted!
Step 7, Make sure the shaft is not desturbed when re fitting! Align the HPFP and gently make push the pump back into its position (refer to step 3 if it sits out to far! remember the spring may have full lift on it!) start the 3 torx bolts by fingers and eveny wind them in to seat the HPFP into its original position then finnally nip the bolts back up. (some one might like to add tensions to this) A 1/4' rachet is perfect.
Step 8, You can now reconnect all the fuel lines and sensor paying attention to the fuel clips as mentioned above, reconnect your battery ( make sure you dont have fuel everywhere ) Turn your igniton to the reds and allow the fuel system to prime, check to see that you have no fuel leaks from the lines before starting! If you are confident that all is well start your car!
Although that sounds like alot of work this could be done in around an hour, its not a race though so take your time and enjoy DIY!