FUEL PUMP(for High Pressure) INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY


    1. B008LDFC03
      *1 Fuel Pump Lifter Guide
      *2 Fuel Pump Lifter Assembly
      *3 Camshaft
      *a Correct
      *b Incorrect

      Turn the crankshaft pulley until the flat of the camshaft faces the fuel pump lifter assembly.

      Tech Tips

      This prevents the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly.

    2. Apply engine oil to a new O-ring and install it to the fuel pump assembly.

    3. B008K5DC04
      *1 Fuel Pump Assembly
      *2 Fuel Pump Lifter Assembly
      *3 Fuel Pump Lifter Guide
      *a O-ring
      *b Engine Oil Application Area

      Apply engine oil to the O-ring of the fuel pump assembly, inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.

    4. Install the fuel pump lifter assembly to the fuel pump lifter guide.

    5. Install the fuel pump assembly to the fuel pump lifter guide.

    6. B008LQZC02
      *1 Cylinder Head Cover Sub-assembly
      *2 O-ring
      *3 Fuel Pump Spacer Gasket
      *a No. 4 Camshaft Bearing Cap
      *b Pump Drive Cam (Engine Oil Application Area)
      *c Pump Lifter (Engine Oil Application Area)
      *d Knock Pin
      *e Pin Hole

      Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam.

    7. Apply engine oil to the fuel pump lifter assembly.

    8. Apply engine oil to 2 new O-rings and install them to the No. 4 camshaft bearing cap.

    9. Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.

    10. Set the fuel pump assembly and fuel pump protector on the cylinder head cover sub-assembly.

      Tech Tips

      Align the pin holes of the fuel pump lifter guide with the knock pins of the No. 4 camshaft bearing cap.

    11. Temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement.

  2. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

    Note

    Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly when installing.


    1. Temporarily install the bolt.

    2. Connect the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.

    3. Connect the No. 1 fuel pipe sub-assembly to the fuel delivery pipe sub-assembly and tighten the union nut by hand.

  3. INSTALL FUEL PUMP ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing the fuel pump assembly.

    Click here


    1. B008KWMN01

      Tighten the bolt (B).

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Tighten the 2 bolts (A).

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    3. Connect the fuel pump assembly connector.

  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B008KBIC02
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length
      B008MD9 Union Nut
      B008LL0 Bolt

      Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

      Torque:
      Specified tightening torque
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

    2. Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

      Torque:
      Specified tightening torque
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

    3. Tighten the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. CONNECT FUEL TUBE SUB-ASSEMBLY

    Note

    Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


    1. Connect the fuel tube sub-assembly to the fuel pump assembly.


      1. B008MA1C02
        *a Retainer
        *b Fuel Tube Connector
        *c Nylon Tube
        *d O-ring
        *e Fuel Pipe
        B008MD9 Push
        B008LL0 Push in

        Engage the clamp to connect the fuel tube sub-assembly.

      2. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

      3. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

  6. INSTALL INTAKE MANIFOLD

    Click here

  7. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  8. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  9. INSTALL RADIATOR COVER

    Click here

  10. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  11. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  12. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  13. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  14. INSTALL WATER GUARD PLATE LH

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  15. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  16. INSTALL WINDSHIELD WIPER MOTOR AND LINK

    Click here

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  18. INSPECT FOR FUEL LEAK

    Click here

  19. PERFORM INITIALIZATION


    1. Perform "Inspection After Repair" after replacing the fuel pump assembly.

      Click here