FUEL RELIEF VALVE INSTALLATION


  1. INSTALL FUEL RELIEF VALVE ASSEMBLY


    1. Install a new O-ring, new backup rings (No. 1, No. 2 and No. 3) and a new E-ring to the fuel relief valve as shown in the illustration.

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      Note


      • Check that there is no foreign matter or damaged areas in the relief valve'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.

      • Check that the No. 3 fuel pipe installation end is not contaminated with foreign matter and is not damaged.

    2. Fix the delivery pipe between aluminum plates in a vise.

      Note

      Do not overtighten the vise.

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      Apply engine oil to the O-ring. Using a 5 mm hexagon socket wrench, install the fuel relief valve to the fuel delivery pipe with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note

      Make sure there is no gasoline on the O-ring and inside the installation hole.

  2. INSTALL FUEL DELIVERY PIPE


    1. Install 4 new injector vibration insulators to the cylinder head.

    2. Apply lubricant to the fuel injector seals and installation holes.

    3. Install the fuel delivery pipe (with fuel injector assemblies) to the cylinder head with the 5 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note


      • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.

      • Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the cylinder head.

      • When inserting the fuel delivery pipe, push it in evenly without tilting it.

    4. Connect the 4 fuel injector connectors.

    5. Connect the No. 3 fuel hose and fuel relief valve connector.

  3. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY

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    Text in Illustration
    *1 Union Nut Wrench
    *2 Separator Case
    *3 Fuel Pipe Protector

    1. Temporarily install the No. 4 fuel pipe sub-assembly.

    2. Using a 19 mm union nut wrench, tighten the No. 4 fuel pipe sub-assembly in the order shown in the illustration.

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

      Note


      • After installing the No. 4 fuel pipe sub-assembly, check that the fuel pipe protector contacts with the separator case.

      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

      Tech Tips

      Make sure use the union nut wrench and torque wrench are connected in a straight line.

  4. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH

  5. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY

  6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

  7. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  8. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    Click here