FUEL PUMP(for High Pressure) INSTALLATION

PROCEDURE


  1. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY


    1. A002173C03
      *1 Fuel Pump lifter guide
      *2 Fuel Pump lifter assembly
      *a Cam Lobe
      *b Correct
      *c Incorrect

      Turn the crankshaft pulley so that the flat surface of the cam lobe faces upward from the fuel pump with seal sub-assembly installation hole of the cylinder head cover sub-assembly.

      Tech Tips

      By performing the above procedure, the cam lobe nose does not push up the drive face of the fuel pump with seal sub-assembly when installing the fuel pump with seal sub-assembly.

    2. A002147C02
      *1 Cylinder Head Cover Sub-assembly
      *2 Pump Housing
      *3 O-ring
      *4 Fuel Pump Spacer Gasket
      *a Pump Drive Cam (Engine Oil Application Point)
      *b Pump Lifter (Engine Oil Application Point)
      *c Knock Pin
      *d Positioning Knock Hole

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

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

    4. Apply engine oil to the 2 new O-rings and install it to the pump housing.

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

    6. A0021IPC02
      *1 Fuel Pump with Seal Sub-assembly
      *2 O-ring
      *3 Fuel Pump Insulator
      *4 Fuel Pump Lifter Assembly
      *5 Fuel Pump Lifter Guide
      A0021RS Engine Oil Application Point

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

    7. Remove the fuel pump lifter assembly from the fuel pump lifter guide.

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

    9. Install the fuel pump lifter assembly to the fuel pump lifter guide.

    10. Install the fuel pump insulator to the fuel pump lifter guide.

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

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

  2. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


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

    2. Temporarily install the union nuts on the fuel pump with seal sub-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.

  3. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

    Tech Tips

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



    1. A0022BTN01

      Install the fuel pump with seal sub-assembly by uniformly tightening the 2 bolts in several steps in the order shown in the illustration.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    2. Tighten the 2 bolts in the order shown in the illustration again.

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

    3. Connect the fuel pump with seal sub-assembly connector.

  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. Using a 17 mm union nut wrench, tighten the union nuts on the fuel pump with seal sub-assembly side of the No. 1 fuel pipe sub-assembly.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note


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

        Click here

      • Do not adjust the torque in the loosening direction.

      • The No. 1 fuel pipe sub-assembly can be reused 10 times.

      Tech Tips


      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

      • Install the union nut wrench parallel with the torque wrench.

    2. Using a 17 mm union nut wrench, tighten the union nuts on the fuel delivery pipe sub-assembly side of the No. 1 fuel pipe sub-assembly.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note


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

        Click here

      • Do not adjust the torque in the loosening direction.

      • The No. 1 fuel pipe sub-assembly can be reused 10 times.

      Tech Tips


      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

      • Install the union nut wrench parallel with the torque wrench.

  5. INSTALL NO. 1 FUEL PIPE


    1. A0021OHC02
      *a Stopper

      Type A:


      1. Temporarily install the No. 1 fuel pipe and 2 new gaskets with the union bolt.

        Note

        The stopper of the No. 1 fuel pipe must contact the fuel pump with seal sub-assembly.

      2. Tighten the union bolt.

        Torque:
        35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    2. Type B and Type C:


      1. A00228RC02
        *A Type B
        *B Type C
        *a Gasket Type

        Install the No. 1 fuel pipe and a new gasket to the fuel pump with seal sub-assembly.

        Torque:
        Type B
        47 N*m  { 479 kgf*cm, 35 ft.*lbf }
        Type C
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

        Note

        Confirm the type of the gasket before installation.

  6. CONNECT FUEL TUBE SUB-ASSEMBLY


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

      Note

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


      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

        A00239PC02
        *A Type A *B Type B and Type C
        *a Retainer *b Nylon Tube
        *c Fuel Pipe *d O-ring
        *e Fuel Tube Connector - -

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Push in the fuel tube connector cover.

  7. INSTALL INTAKE MANIFOLD

    Click here

  8. PERFORM INITIALIZATION


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