FUEL PUMP(for High Pressure) INSTALLATION

PROCEDURE


  1. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY


    1. B004GS5C06
      *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 prevent the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump with seal sub-assembly.

    2. B004FNXC02
      *1 Fuel Pump with Seal Sub-assembly
      *2 O-ring
      *3 Fuel Pump Insulator
      *4 Fuel Pump Lifter Assembly
      *5 Fuel Pump Lifter Guide
      B004FVZ Engine Oil Application Area

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

    3. Remove the fuel pump lifter assembly from the fuel pump lifter guide.

    4. Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.

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

    6. Install the fuel pump insulator to the fuel pump lifter guide.

    7. Install the fuel pump with seal sub-assembly to the fuel pump lifter guide.

    8. B004FAXC02
      *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 Point)
      *c Pump Lifter (Engine Oil Application Point)
      *d Knock Pin
      *e Pin Hole

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

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

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

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

    12. Set the fuel pump with seal sub-assembly 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.

    13. Temporarily install the fuel pump with seal sub-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. Connect the No. 1 fuel pipe sub-assembly to the fuel delivery pipe sub-assembly and tighten the union nut by hand.

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

  3. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing the fuel pump with seal sub-assembly.

    Click here


    1. B004FBAN01

      Install the fuel pump with seal sub-assembly by uniformly tightening the 2 bolts in several steps in the order shown in the illustration.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    2. Tighten the 2 bolts in the order shown in the illustration again.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    3. Connect the fuel pump with seal sub-assembly connector.

  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B004GL4C02
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the union nut on the fuel pump with seal sub-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)

    2. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe sub-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)

  5. INSTALL NO. 1 FUEL PIPE


    1. Install the No. 1 fuel pipe and a new gasket to the fuel pump with seal sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  6. 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 No. 1 fuel pipe.


      1. B004FEIC02
        *a Retainer
        *b Fuel Tube Connector
        *c Nylon Tube
        *d O-ring
        *e Fuel Pipe

        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 engine oil to the tip of the fuel pipe and reinsert it.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Push in the fuel tube connector cover.

  7. INSTALL INTAKE MANIFOLD

    Click here

  8. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

    Click here

  9. INSTALL BATTERY SERVICE HOLE COVER LH

    Click here

  10. INSPECT FOR FUEL LEAK

    Click here

  11. PERFORM INITIALIZATION


    1. Perform "Inspection After Repair" after replacing the fuel pump with seal sub-assembly.

      Click here