High Pressure Fuel Pump

This procedure replaces the high pressure fuel pump on the 1.5L turbo engine, which is camshaft-driven and located on the cylinder head. This is a safety-critical fuel system repair requiring precise torque specifications and fuel pressure relief.

Warnings

Tools required

Parts

• High pressure fuel pump assembly × 1 — 16700-5AA-A01 or equivalent OEM
• Fuel pump O-ring kit × 1 — Use Honda OEM O-ring set
• Fuel line O-rings × 2 — Use Honda OEM specification
• Fuel pump gasket × 1 — Use Honda OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake. Ensure transmission is in Park (automatic) or neutral (manual).
2. Disconnect negative battery cable and wait 3 minutes for airbag system capacitors to discharge.
3. Ensure engine is completely cold (wait at least 3 hours after operation).
4. Remove engine cover by pulling upward on front edge, then lifting entire cover off.
5. Place fire extinguisher within immediate reach of work area.
6. Prepare catch pan and absorbent towels for fuel spillage.
7. Verify you have new O-rings and gasket before beginning disassembly.

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay in the under-hood fuse box (relay R25, labeled 'FUEL PUMP'). Remove the fuel pump relay. Attempt to start the engine; it should start briefly then stall as fuel pressure drops. Crank the engine for an additional 5 seconds to ensure complete depressurization. Turn ignition OFF. Disconnect the negative battery terminal if not already done.
   ⚠️Do NOT skip this step. Unpressurized fuel system is mandatory before disconnecting any fuel lines.
2. 2

   Remove ignition coil covers and coils
   Remove the four ignition coil cover screws using a Phillips screwdriver. Lift off the cover. Disconnect the electrical connectors from all four ignition coils by pressing the release tab and pulling straight up. Remove each ignition coil by pulling straight up with steady force. Set coils aside in order.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
3. 3

   Remove PCV hose and vacuum lines
   Disconnect the PCV hose from the intake manifold side by squeezing the clamp and sliding it back, then pull hose off. Disconnect any vacuum lines attached to the intake manifold above the fuel pump area. Label connections if necessary for reassembly. Move hoses aside to access fuel pump area.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect high pressure fuel line
   Place catch pan under the high pressure fuel line connection at the fuel pump (front of pump, on cylinder head). The connection has a quick-connect fitting. Using the appropriate fuel line disconnect tool, slide it over the line and press the release tabs while pulling the line away from the pump. Expect residual fuel spillage. Allow fuel to drain into catch pan. Inspect the old O-ring and discard it.
   ⚠️Wear safety glasses. Residual fuel under pressure may spray when connection is released.
   ⚠Do not use regular pliers or tools that can damage the quick-connect fitting.
5. 5

   Disconnect fuel pump electrical connector
   Locate the electrical connector on the side of the high pressure fuel pump. Press the release tab and carefully pull the connector straight away from the pump. Do not pull on wires. Move the wiring harness aside to provide clearance.
6. 6

   Remove fuel pump mounting bolts
   The high pressure fuel pump is secured by two mounting bolts accessible from above. Using a 12mm socket, remove both bolts completely. Keep bolts in a clean location for inspection and potential reuse. Note the position and orientation of any brackets or washers.
   ⚠Support the pump with one hand while removing the second bolt to prevent it from falling.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
7. 7

   Remove high pressure fuel pump
   Carefully pull the fuel pump assembly straight out from the cylinder head. The pump drive mechanism is engaged with the camshaft, so it will require firm, steady pulling. Rock gently side-to-side if needed, but do not pry against the cylinder head. Once removed, immediately place pump on clean shop towels. Remove and discard the old gasket and O-ring from the cylinder head mounting surface.
   ⚠Fuel will drain from the pump. Keep catch pan positioned to collect spillage.
   ⚠Do not allow dirt or debris to enter the cylinder head opening.
8. 8

   Clean mounting surface and inspect camshaft lobe
   Using clean, lint-free towels, thoroughly clean the fuel pump mounting surface on the cylinder head. Remove all old gasket material. Inspect the camshaft lobe that drives the fuel pump (visible in the mounting bore). The lobe should be smooth with no scoring, pitting, or excessive wear. If cam lobe is damaged, engine disassembly is required - do not proceed. Ensure no debris or towel fibers remain in the opening.
   ⚠Cover the opening with a clean towel when not actively working to prevent foreign material entry.
9. 9

   Prepare new fuel pump
   Unpack the new high pressure fuel pump. Install the new gasket onto the pump mounting flange, ensuring it seats properly in the groove. Install the new large O-ring onto the pump body. Lightly lubricate the O-ring with clean engine oil to prevent damage during installation. Verify the pump drive mechanism moves freely and is not damaged.
   ⚠Do not use petroleum jelly or non-compatible lubricants on O-rings. Use only clean engine oil.
10. 10

    Install new high pressure fuel pump
    Align the fuel pump drive mechanism with the camshaft lobe. The pump has a specific orientation - the electrical connector should face toward the front of the engine. Carefully push the pump into the cylinder head while rotating it slightly to engage the drive mechanism with the camshaft. Push firmly until the pump mounting flange is flush with the cylinder head surface and the gasket is fully seated.
    ⚠️Ensure pump is fully seated before installing bolts. Partial engagement can cause pump failure and engine damage.
11. 11

    Install pump mounting bolts
    Thread both mounting bolts by hand to ensure proper thread engagement. Using a torque wrench and 12mm socket, tighten the mounting bolts in a cross-pattern to the specified torque of 26 Nm (19 lb-ft). Verify the pump is properly seated and does not move when tugged gently.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
12. 12

    Connect high pressure fuel line
    Install a new O-ring onto the high pressure fuel line fitting. Lightly lubricate the O-ring with clean engine oil. Align the fuel line with the pump connection and push firmly until you hear and feel a distinct click, indicating the quick-connect fitting is locked. Gently tug on the line to verify it is securely connected.
    ⚠The O-ring must be properly seated in the fitting groove before connection. A missing or damaged O-ring will cause high-pressure fuel leaks.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
13. 13

    Reconnect electrical connector
    Plug the electrical connector back onto the fuel pump until you hear a click. Ensure the connector lock tab is fully engaged. Give the connector a gentle pull to confirm it is secure.
14. 14

    Reinstall ignition coils and covers
    Reinstall each ignition coil into its cylinder in the correct order, pushing down firmly until fully seated. Reconnect all four ignition coil electrical connectors. Position the ignition coil cover and install the four cover screws. Torque the cover screws to 10 Nm (8 lb-ft).
    Torque spec

    Cover Screws10 Nm (8 lb-ft)
15. 15

    Reconnect vacuum lines and PCV hose
    Reconnect all vacuum lines to their original positions. Reinstall the PCV hose to the intake manifold, sliding the hose clamp into position and ensuring it is secure. Torque hose clamps to 3 Nm (2 lb-ft) if using new clamps with torque capability.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Reinstall the fuel pump relay (R25) in the under-hood fuse box.
2. Reconnect the negative battery cable.
3. Reinstall the engine cover by aligning the mounting grommets and pressing down firmly until all attachment points click into place.
4. Do NOT start the engine yet - proceed to verification steps first.

Verification

• Turn the ignition key to ON position (do not start engine) for 2 seconds, then OFF. Repeat this cycle 3-4 times to allow the fuel pump to prime and pressurize the system.
• Perform a careful visual inspection of all fuel line connections, specifically the high pressure line at the pump. Look for any signs of fuel wetness or leakage.
• Check around the fuel pump mounting area for any fuel seepage from the gasket or O-ring.
• With catch pan still positioned under fuel pump area, start the engine and let it idle. Immediately inspect all connections for leaks during the first 30 seconds of operation.
• If any fuel leakage is observed, immediately shut off the engine, relieve fuel pressure, and inspect connections and O-rings.
• Allow engine to idle for 5 minutes while monitoring for leaks, unusual noises from the fuel pump area, or check engine light.
• With engine running, verify smooth idle with no misfires or fuel pressure-related codes.
• Turn off engine and perform final inspection for fuel leaks after engine is off.
• Test drive the vehicle and monitor for any fuel smell, hesitation, or check engine light. Fuel pump issues typically manifest as poor acceleration or stumbling under load.
• After test drive, perform final cold inspection of all fuel connections before returning vehicle to service.

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