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FUEL PUMP(for High Pressure) INSTALLATION

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CAUTION / NOTICE / HINT

Tip:

Perform "Inspection After Repairs" after replacing the fuel injector assembly.


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PROCEDURE


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    SET FUEL PUMP ASSEMBLY


    1. B004T0PC03
      *1 Camshaft
      *2 Fuel Pump Assembly
      *3 Fuel Pump Lifter Assembly
      *a Correct
      *b Incorrect
      *c Oil Collection Area

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

      Tip:

      By performing the above procedure, the protruding part of the camshaft does not push up the drive face of the fuel pump when installing the fuel pump, thus making installation of the fuel pump and No. 1 fuel pipe sub-assembly easier.

    2. Fill the fuel pump lifter housing oil collection areas with 30 cc (1.8 cu. in.) of engine oil from the fuel pump assembly hole of the cylinder head cover sub-assembly.

    3. B004TEQC03
      *1 Cylinder Head Cover Sub-assembly
      *2 Fuel Pump Housing
      *3 Fuel Pump Spacer Gasket
      *a Pump Drive Cam (Engine Oil Application Area)
      *b Fuel Pump Lifter Assembly (Engine Oil Application Area)

      Apply engine oil to the pump drive cam and fuel pump lifter assembly.

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

    5. B004VLDC04
      *a Fuel Pump Lifter Assembly (Engine Oil Application Area)
      *b Fuel Pump Lifter Housing (Engine Oil Application Area)
      *c Stopper Key
      *d Key Groove

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

    6. Set the fuel pump lifter assembly on the fuel pump lifter housing as shown in the illustration.

      Tip:

      Align the stopper key of the fuel pump lifter assembly with the key groove of the fuel pump lifter housing.

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

      Note:

      Do not damage the O-ring.

    8. B004TI3C04
      *1 Fuel Pump Assembly
      *2 Fuel Pump Lifter Guide

      Set the fuel pump lifter guide and fuel pump assembly on the cylinder head cover sub-assembly as shown in the illustration.

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

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    TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. Temporarily install the union nuts on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly until they are completely tightened.

      Note:

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

    2. Temporarily install the union nuts on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly until they are completely tightened.

      Note:

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

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    INSTALL FUEL PUMP ASSEMBLY

    Tip:

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



    1. Tighten the 2 bolts.

      26 N*m 265 kgf*cm 19 ft.*lbf

    2. Connect the fuel pump assembly connector.

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    INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B004VFJC27
      *a Torque Wrench Fulcrum Length

      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.

      Specified tightening torque
      35 N*m 357 kgf*cm 26 ft.*lbf
      Note:

      Do not adjust the torque in the loosening direction.

      Tip:

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

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      • 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 RH side of the No. 1 fuel pipe sub-assembly.

      Specified tightening torque
      35 N*m 357 kgf*cm 26 ft.*lbf
      Note:

      Do not adjust the torque in the loosening direction.

      Tip:

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

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      • 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)

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    INSTALL FUEL MAIN TUBE CONNECTOR


    1. Install the fuel main tube connector to the fuel pump assembly.

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    CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. Connect the No. 2 fuel tube sub-assembly to the fuel pump assembly.

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    2. Attach the clamp.

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    INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe to the cylinder head sub-assembly with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
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    INSTALL INTAKE MANIFOLD

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    INSTALL EGR COOLER ASSEMBLY

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    CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note:

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

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    INSPECT FOR FUEL LEAK

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