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Autopapyrus · Chery Arrizo 8 1.6 Turbo (2023)
https://autopapyrus.com/guides/chery/arrizo-8/high-pressure-fuel-pump-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Chery Arrizo 8 1.6 Turbo (2023): High-Pressure Fuel Pump Replacement

The SQRF4J16 1.6 Turbo engine uses a direct injection system with pressure up to 350 bar. The high-pressure fuel pump is driven by the camshaft through a cam follower and is mounted on the cylinder head. Replacement requires relieving the fuel system pressure, removing the high-pressure lines, and following the specified torque values.

Difficulty: Hard Time: 2-4 hours Steps: 19 Tools: socket and wrench set, torque wrench, fuel line disconnect tools, safety glasses, shop rags

Part

  • 🔩 High-pressure fuel pump for the SQRF4J16 engine. Be sure to also replace the pump cam follower and the high-pressure fuel lines (single-use seals)

Step by step

19 steps
  1. Relieve the residual pressure in the fuel system: locate the fuel pump fuse in the under-hood fuse box or the cabin fuse box, remove it, start the engine, and let it stall on its own. This lowers the pressure in the lines to a safe level.
  2. Disconnect the negative battery terminal and wait 2-3 minutes for the electronics to fully power down.
  3. Remove the decorative engine cover (it is held by rubber grommets or clips).
  4. Locate the high-pressure fuel pump on the cylinder head (usually on the right side in the direction of travel, under or next to the turbocharger). The pump is connected to the fuel rail by a high-pressure line.
  5. Disconnect the pump's electrical connector (press the locking tab and pull).
  6. Disconnect the fuel lines: the low-pressure line (from the fuel tank to the pump) by unscrewing the quick-connect fitting or the flare nut; the high-pressure line (from the pump to the rail) using a special high-pressure line wrench. Place rags underneath, since residual fuel will leak out.
  7. Remove the bolts securing the pump to the cylinder head (usually 2-3 M8 or M10 bolts). For the installation torque, check the manufacturer's service manual (typically 15-25 N·m (11-18 lb-ft)).
  8. Carefully lift the pump straight up without tilting it. Inside is a cam follower (roller or mushroom type) that rests on the camshaft lobe, and it may fall out when you remove the pump.
  9. Remove the follower from its bore in the cylinder head. Inspect its working surface for scoring, wear, and pitting. Use a flashlight to check the camshaft lobe: if it is worn (grooves, chips), the camshaft will need replacement or the cylinder head will need repair.
  10. Replace the cam follower with a new one (mandatory, even if the old one looks fine, otherwise the new pump will wear out quickly). Install the new follower in the bore.
  11. Coat the working surface of the new follower with a thin layer of engine oil or special assembly lube to prevent a dry start.
  12. Install the new high-pressure fuel pump straight down into its seat, aligning the pump plunger with the follower. Start the mounting bolts by hand, then tighten them in a crisscross pattern with a torque wrench to the specified torque (typically 15-25 N·m (11-18 lb-ft); the exact value is in the manufacturer's documentation).
  13. Replace the high-pressure fuel lines with new ones. The old lines have single-use sealing rings that deform when tightened. Reusing them will cause a high-pressure fuel leak and a risk of fire.
  14. Connect the new high-pressure line to the pump and the rail, and tighten the flare nuts to the specified torque (typically 20-30 N·m (15-22 lb-ft) for high-pressure lines).
  15. Connect the low-pressure line and the pump's electrical connector.
  16. Install the decorative engine cover, reconnect the negative battery terminal, and put the fuel pump fuse back in.
  17. Turn the ignition on for 3-5 seconds without starting the engine (2-3 times) to build pressure in the system. Visually inspect the fuel line connections for leaks.
  18. Start the engine and let it idle for 2-3 minutes. Check that it runs smoothly, with no fuel leaks and no unusual noises from the high-pressure pump.
  19. Take a test drive under various conditions (idle, gentle acceleration, hard acceleration). Make sure there are no Check Engine codes, hesitation, or loss of power.

Common mistakes and warnings

  • A GDI fuel system operates at pressures up to 350 bar, which is about 7 times higher than a hydraulic press. Failing to relieve the pressure properly or reusing single-use lines can cause a high-pressure fuel spray, a fire, or injury. If you have no experience with high-pressure systems or do not have a torque wrench, take the car to a qualified repair shop. If you find camshaft lobe wear, do not install a new pump until the cylinder head is repaired, or the pump will fail again quickly.