FUEL PUMP (for High Pressure) INSTALLATION

INSTALL FUEL PUMP ASSEMBLY (for Bank 1)
1. Turn the camshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.
  
  Tech Tips
  
  By not using the camshaft lobe to push up the pump lifter surface, it is easier to install the fuel pump and No. 3 fuel pipe later.
2. Pour 30 cm³(1.8 cu. in.) of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.
3. Apply a coat of engine oil to the pump activation cam and pump lifter.
4. Install a new fuel pump insulator to the cylinder head cover. Then pass the 2 stud bolts through the holes of the fuel pump and set them on the insulator.
  
  Note
  
  Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.
5. Temporarily install the fuel pump with the 2 nuts.
6. Connect the fuel hose.
INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY
1. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown in the illustration.
  Note
  
  Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
  
  Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
  
  Make sure that the backup rings and O-ring are installed in the correct order.
  
  Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
  
  After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
2. Apply engine oil to the O-ring.
  
  Note
  
  Make sure there is no gasoline on the O-ring and inside the installation hole.
3. Temporarily install the No. 3 fuel pipe to the delivery pipe with the 2 bolts.
4. Temporarily install the No. 3 fuel pipe sub-assembly to the fuel pump.
  
  Note
  
  Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
5. Tighten the 2 bolts in several passes.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
6. Tighten the 2 nuts in several passes.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
7. Using a 19 mm union nut wrench, tighten the union nut.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  Note
  - There must be absolutely no free play in the union on the fuel pump side. If the union on the fuel pump side has free play, replace the fuel pump.
  - Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
8. Connect the fuel pump connector.
INSTALL COVER SUB-ASSEMBLY (for Bank 1)
1. Attach the 5 claws and install the engine cover LH and RH to the fuel pump.
INSTALL FUEL PUMP ASSEMBLY (for Bank 2)

Tech Tips

The installation procedures are the same as the bank 1 side.
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

Tech Tips

The installation procedures are the same as the No. 3 fuel pipe sub-assembly.
INSTALL COVER SUB-ASSEMBLY (for Bank 2)

Tech Tips

The installation procedures are the same as the bank 1 side.
INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

Click here
INSPECT FOR FUEL LEAK
1. Connect the intelligent tester to the DLC3.
2. Turn the engine switch on (IG).
  
  Note
  
  Do not start the engine.
3. Turn the intelligent tester on.
4. Select the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.
5. Check the fuel pump operation.
  1. Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard.
    
    If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.
6. Check for fuel leaks.
  1. Check that there are no fuel leaks anywhere on the system after performing maintenance.
    
    If there is a fuel leak, repair or replace parts as necessary.