FUEL PUMP(for High Pressure) INSTALLATION

PROCEDURE


  1. SET FUEL PUMP ASSEMBLY


    1. B00593QC02
      *1 Fuel Pump lifter guide
      *2 Fuel Pump lifter assembly
      *3 Camshaft
      *a Correct
      *b Incorrect

      Turn the crankshaft pulley so that the flat surface of the cam lobe faces upward from the fuel pump 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 assembly when installing the fuel pump assembly.

    2. B0058FSC02
      *1 Cylinder Head Cover Sub-assembly
      *2 O-ring
      *3 Gasket
      *a Pump Housing
      *b Knock Pin
      *c Pump Drive Cam (Engine Oil Application Point)
      *d Positioning Knock Hole
      *e Pump Lifter (Engine Oil Application Point)

      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 gasket to the cylinder head cover sub-assembly.

    6. B005925C02
      *1 Fuel Pump Assembly
      *2 O-ring
      *3 Fuel Pump Lifter Assembly
      *4 Fuel Pump Lifter Guide
      *a Engine Oil Application Point

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

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

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

    9. Set the fuel pump assembly on the cylinder head cover sub-assembly.

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

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

    Note

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


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

    2. 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.

  3. INSTALL FUEL PUMP ASSEMBLY

    Tech Tips

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



    1. B005A29N02

      Install the fuel pump 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 connector to the fuel pump assembly.

  4. TIGHTEN NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B005A9MC01
      *a Torque Wrench Fulcrum Length

      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:
      Specified tightening torque
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips


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

        Click here

      • When using a 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. B005A9MC01
      *a Torque Wrench Fulcrum Length

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

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

      Tech Tips


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

        Click here

      • When using a 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)

  5. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel pump assembly.

      Click here

  6. INSTALL BRACKET


    1. Using an E8 "TORX" socket wrench, install the stud bolt to the cylinder head sub-assembly.

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

    2. Install the bracket to the cylinder head sub-assembly with the bolt.

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

  7. INSTALL FUEL PUMP PROTECTOR


    1. Install the fuel pump protector to the bracket and cylinder head sub-assembly with the bolt and nut.

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

  8. INSTALL INTAKE MANIFOLD

    Click here

  9. INSPECT FOR FUEL LEAK

    Click here

  10. PERFORM INITIALIZATION


    1. Perform "Inspection After Repair" after replacing the fuel pump assembly.