FUEL PUMP(for High Pressure) INSTALLATION

PROCEDURE


  1. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 1)


    1. B000VP6C04
      *1 Fuel Pump Lifter Guide
      *2 Fuel Pump Lifter Assembly
      *a Cam Lobe
      *b Correct
      *c Incorrect

      Turn the crankshaft pulley until the flat of the cam lobe faces the fuel pump with seal sub-assembly installation hole of the cylinder head cover sub-assembly LH.

      Tech Tips

      This prevent the cam nose from pushing up the pump lifter when installing the fuel pump with seal sub-assembly.

    2. B000UCTC02
      *1 Fuel Pump with Seal Sub-assembly
      *2 O-ring
      *3 Fuel Pump Insulator
      *4 Fuel Pump Lifter Assembly
      *5 Fuel Pump Lifter Guide
      B000XQF Engine Oil Application Area

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

    3. Apply engine oil to the 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 insulator to the fuel pump lifter guide.

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

    7. B000V53C01
      *1 Cylinder Head Cover Sub-assembly LH
      *2 O-ring
      *3 Fuel Pump Spacer Gasket
      *4 No. 4 Camshaft Bearing Cap
      *a Pump Drive Cam (Engine Oil Application Area)
      *b Pump Lifter (Engine Oil Application Area)
      *c Knock Pin
      *d Pin Hole

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

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

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

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

    11. Set the fuel pump with seal sub-assembly on the cylinder head cover sub-assembly LH.

    12. Temporarily install the fuel pump with seal sub-assembly with the 2 bolts, leaving some allowance for left and right movement.

  2. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 2)

    Tech Tips

    Use the same procedure as for the bank 1 side.

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


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

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

      Note

      Do not damage the seals of the union nuts of the No. 2 fuel pipe sub-assembly when installing.

    3. Temporarily install the bolt.

  4. TEMPORARILY INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY


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

    2. Connect the No. 3 fuel pipe sub-assembly to the fuel pump with seal sub-assembly and tighten the union nut by hand.

      Note

      Do not damage the seals of the union nuts of the No. 3 fuel pipe sub-assembly when installing.

    3. Temporarily install the bolt.

  5. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 1)


    1. Tighten the 2 bolts.

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

  6. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 2)

    Tech Tips

    Use the same procedure as for the bank 1 side.

  7. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. B000V3MC01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the union nuts on the fuel pump with seal sub-assembly side of the No. 2 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 nuts on the fuel delivery pipe RH side of the No. 2 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 }

  8. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. B000WG5C01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the union nuts on the fuel pump with seal sub-assembly side of the No. 3 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 nuts on the fuel delivery pipe LH side of the No. 3 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 }

  9. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B000XOGC01
      *1 No. 1 Fuel Pipe Sub-assembly
      *2 Gasket

      Install 2 new gaskets to the No. 1 fuel pipe sub-assembly.

    2. B000W30C04
      *1 Union Bolt
      *2 Bolt
      *a Protrusion
      *b Protrusion Area

      Install the No. 1 fuel pipe sub-assembly with the 4 bolts.

      Torque:
      for Union Bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      for Bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      Install the gaskets within the area shown in the illustration.

  10. INSTALL NO. 3 COVER SUB-ASSEMBLY


    1. Install the No. 3 cover sub-assembly to the No. 1 fuel pipe sub-assembly with the 2 clips.

    2. B000TR2C01
      *1 No. 2 Engine Wire
      *a 10 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, install the wire harness bracket to the cylinder head sub-assembly with the 2 bolts.

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

      Tech Tips


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

        Click here

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 155 mm (6.1 in.)): 9.0 N*m (92 kgf*cm, 80 in.*lbf)

    3. Using a 10 mm union nut wrench, connect the No. 2 engine wire with the bolt.

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

      Tech Tips


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

        Click here

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 155 mm (6.1 in.)): 9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Engage the clamp to connect the engine wire to the wire harness bracket.

  11. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Install the No. 1 engine cover sub-assembly.

  12. CONNECT INLET HEATER WATER HOSE

    Click here

  13. CONNECT OUTLET HEATER WATER HOSE

    Click here

  14. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Click here

  15. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. B000TU7C01
      *a Retainer
      *b Fuel Tube Connector
      *c Nylon Tube
      *d O-ring
      *e Fuel Pipe

      Connect the fuel tube sub-assembly to the No. 1 fuel pipe sub-assembly.

      Click here

      Note

      Check if there is any damage or foreign matter on the connecting parts of the fuel pipe.

    2. Attach the clamp to connect the fuel tube sub-assembly to the engine wire.

  16. 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

  17. INSPECT FOR FUEL LEAK

    Click here

  18. PERFORM INITIALIZATION


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