FUEL PUMP(for High Pressure) INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Install a new O-ring, new No. 1 back-up ring, new No. 2 back-up ring, new No. 3 back-up ring and new E-ring to the No. 2 fuel pipe sub-assembly as shown in the illustration.

      B003TFAC05
      *1 No. 1 Back-up Ring *2 No. 2 Back-up Ring
      *3 No. 3 Back-up Ring *4 O-ring
      *5 E-ring - -
      *a Alignment Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -

      Note


      • Check that there is no foreign matter or damage on the O-ring groove of the No. 2 fuel pipe sub-assembly.

      • Check that the No. 1 back-up ring and No. 2 back-up ring are installed in the correct direction.

      • Make sure that the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and O-ring are installed in the correct order.

      • Check that the alignment openings of the back-up 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. 2 fuel pipe sub-assembly installation end is not contaminated with foreign matter and is not damaged.

    2. Apply gasoline to the O-ring and connect the No. 2 fuel pipe sub-assembly to the fuel delivery pipe sub-assembly.

      Note


      • Do not install the No. 2 fuel pipe sub-assembly at an angle.

      • Do not install the bolt at this time.

  2. INSTALL FUEL PUMP ASSEMBLY


    1. B003WKEC04
      *1 Fuel Pump Assembly
      *a Cam Lobe
      *b Oil Collector
      *c Correct
      *d Incorrect

      Turn the crankshaft pulley until the flat of the cam lobe faces the cylinder head cover fuel pump assembly installation hole as shown in the illustration.

      Tech Tips

      When installing the fuel pump assembly by following the procedure described above: By not using the cam lobe nose to push up the pump activation surface, it is easier to install the fuel pump assembly and No. 2 fuel pipe sub-assembly later.

    2. Pour 30 cc (1.8 cu in.) of engine oil through the cylinder head cover sub-assembly fuel pump assembly installation hole into the cylinder head cover sub-assembly oil collector.

    3. B003TGSC02
      *a Cam Lobe
      *b Pump Lifter

      Apply a coat of engine oil to the cam lobe and pump lifter.

    4. B003V2TC02
      *a Metal Eyelets
      B003WAF Stud Bolt

      Install a new fuel pump insulator to the cylinder head cover sub-assembly. Then pass the 2 stud bolts through the holes of the fuel pump assembly and fuel pump insulator.

      Note

      Install the fuel pump insulator so that the open sides of the metal eyelets are facing outward as shown in the illustration.

    5. B003VFH

      Temporarily install the No. 2 fuel pipe sub-assembly to the fuel pump assembly.

      Note

      Be careful not to damage the sealing surface of the No. 2 fuel pipe sub-assembly when temporarily installing the No. 2 fuel pipe sub-assembly.

    6. Install the 2 nuts and tighten them in several steps.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  3. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Install the No. 2 fuel pipe sub-assembly to the fuel delivery pipe sub-assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B003SZ8C01
      *a 19 mm Union Nut Wrench

      Using a 19 mm union nut wrench, connect the No. 2 fuel pipe sub-assembly.

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

      Tech Tips

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

      Click here

    3. Connect the fuel pump assembly connector.

  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. Install the No. 1 fuel pipe sub-assembly with the 2 bolts.

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

    2. Connect the No. 2 fuel hose to the fuel pump assembly and slide the clip to secure it.

    3. Connect the No. 1 fuel hose to the fuel relief valve assembly and slide the clip to secure it.

    4. Connect the No. 3 fuel hose to the No. 1 fuel pipe sub-assembly and slide the clip to secure it.

  5. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    Click here

  6. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Connect the No. 8 water by-pass hose and No. 9 water by-pass hose to the No. 3 water by-pass pipe and slide the 2 clips to secure them.

    2. Install the No. 3 water by-pass pipe to the camshaft housing sub-assembly RH with the bolt.

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

    3. Engage the wire harness clamp to the No. 3 water by-pass pipe.

    4. Connect the inlet heater water hose A and outlet heater water hose A to the No. 3 water by-pass pipe and slide the 2 clips to secure them.

  7. INSTALL INTAKE MANIFOLD

    Click here

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  9. INSPECT FOR FUEL LEAK

    Click here