Fuel Pump (For High Pressure)
REMOVAL1. REMOVE COOL AIR INTAKE DUCT SEAL
2. REMOVE ENGINE ROOM SIDE COVER LH
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE FRONT UPPER FENDER PROTECTOR LH
6. REMOVE FRONT UPPER FENDER PROTECTOR RH
HINT: Removal procedure of the RH side is the same as that of the LH side.
7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH
8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH
HINT: Removal procedure of the RH side is the same as that of the LH side.
9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
13. DISCHARGE FUEL SYSTEM PRESSURE
14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
15. DRAIN ENGINE COOLANT
16. DISCONNECT NO. 2 VENTILATION HOSE
17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
18. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY
19. DISCONNECT COLD START INJECTOR
20. REMOVE INTAKE AIR SURGE TANK
21. REMOVE INTAKE MANIFOLD
22. DISCONNECT WATER HOSE JOINT
23. REMOVE FUEL PRESSURE PULSATION DAMPER
24. REMOVE NO. 1 FUEL PIPE
25. DISCONNECT NO. 2 FUEL PIPE
a. Disconnect the fuel high pressure side fuel pump connector.
b. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.
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.
c. Remove the 2 bolts on the delivery pipe side.
NOTE
- Do not remove the fuel pipe from the delivery pipe. Only remove the 2 bolts.
- If the No. 2 fuel pipe is accidentally removed, replace its O-ring, No. 1 backup ring and No. 2 backup ring.
26. REMOVE FUEL PUMP ASSEMBLY
a. Disconnect the fuel hose.
b. Remove the 2 nuts, fuel pump and fuel pump insulator.
INSTALLATION
1. INSTALL FUEL PUMP ASSEMBLY
a. Turn the crankshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as given in the illustration.
HINT: When installing the fuel pump by given the procedure described above: By not using the crankshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No. 2 fuel pipe later.
b. Pour 30 cc of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.
c. Apply a coat of engine oil to the pump activation cam and pump lifter part.
d. 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 given in the illustration.
e. 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 fuel pipe when temporarily installing the fuel pipe.
f. Install the 2 nuts and tighten them in several passes.
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
g. Connect the fuel hose.
2. CONNECT NO. 2 FUEL PIPE
a. Install the No. 2 fuel pipe to the delivery pipe with the 2 bolts.
Torque: 10 N.m(102 kgf.cm, 7 ft.lbf)
b. Using a 19 mm union nut wrench, connect the fuel pipe.
Torque: 30 N.m(306 kgf.cm, 22 ft.lbf)
c. Connect the connector to the fuel pump.
3. INSTALL NO. 1 FUEL PIPE
4. INSTALL FUEL PRESSURE PULSATION DAMPER
5. CONNECT WATER HOSE JOINT
6. INSTALL INTAKE MANIFOLD
7. INSTALL INTAKE AIR SURGE TANK
8. INSTALL COLD START INJECTOR
9. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY
10. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
11. CONNECT NO. 2 VENTILATION HOSE
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. ADD ENGINE COOLANT
14. CHECK FOR ENGINE COOLANT LEAKAGE
15. CHECK FOR FUEL LEAK
16. CHECK FOR ENGINE OIL LEAKS
17. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
20. INSTALL FRONT WIPER ARM HEAD CAP
21. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
22. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
23. INSTALL FRONT UPPER FENDER PROTECTOR LH
24. INSTALL FRONT UPPER FENDER PROTECTOR RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
25. INSTALL V-BANK COVER SUB-ASSEMBLY
26. INSTALL ENGINE ROOM SIDE COVER LH
27. INSTALL ENGINE ROOM SIDE COVER RH
28. INSTALL COOL AIR INTAKE DUCT SEAL
29. CHECK FUNCTION OF THROTTLE WITH MOTOR BODY ASSEMBLY
30. PERFORM INITIALIZATION
a. Perform initialization.
HINT: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.