Fuel Pump (For High Pressure)
REMOVAL1. PRECAUTION
2. DISCHARGE FUEL SYSTEM PRESSURE
a. Discharge fuel system pressure.
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
4. REMOVE INTAKE MANIFOLD
a. Remove the intake manifold.
5. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
a. Remove the fuel pressure pulsation damper assembly.
6. REMOVE NO.3 FUEL PIPE SUB-ASSEMBLY
a. Remove the high pressure side fuel pump connector.
b. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using SST, loosen the union nut and disconnect the fuel pipe from the fuel pump.
SST 09023-12901
NOTE: Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump.
c. Remove the 2 bolts on the delivery pipe side and remove the fuel pipe.
NOTE: Do not remove the fuel pipe from the delivery pipe. Only remove the 2 bolts. If the No. 3 fuel pipe is accidentally removed, replace its O-ring, No. 1 backup ring and No. 2 backup ring.
7. REMOVE NO.2 FUEL PIPE SUB-ASSEMBLY
HINT: The removal procedures are the same as the No. 3 fuel pipe sub-assembly.
8. REMOVE COVER SUB-ASSEMBLY (for Bank 1)
a. Detach the 5 claws and remove the engine cover LH and RH from the fuel pump.
9. REMOVE COVER SUB-ASSEMBLY (for Bank 2)
HINT: The removal procedures are the same as the bank 1 side.
10. REMOVE FUEL PUMP ASSEMBLY (for Bank 1)
a. Remove the 2 nuts, fuel pump and fuel pump insulator.
b. Disconnect the fuel hose from the fuel pump.
11. REMOVE FUEL PUMP ASSEMBLY (for Bank 2)
HINT: The removal procedures are the same as the bank 1 side.
INSTALLATION
1. INSTALL FUEL PUMP ASSEMBLY (for Bank 1)
a. Turn the camshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.
HINT: By not using the camshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No.3 fuel pipe later.
b. Pour 30 cu.cm (1.8 cu.in) 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 2 nuts and fuel pump.
f. Connect the fuel hose.
2. INSTALL NO.3 FUEL PIPE SUB-ASSEMBLY
a. Install a new O-ring, backup rings (No. 1 and No. 2) and E-ring to the fuel injector as shown in the illustration.
NOTE:
- Check that there is no foreign matter or damaged areas in the injector'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.
b. Temporarily install the No. 3 fuel pipe to the delivery pipe with the 2 bolts.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
c. Temporarily install the No.3 fuel pipe sub-assembly to the fuel pump.
NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
d. Install the No. 3 fuel pipe to the delivery pipe with the 2 bolts and tighten them in several passes.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
e. Install the fuel pump with the 2 nuts and tighten them in several passes.
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
f. Using SST, tighten the union nut.
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Torque:
without SST
30 N.m (306 kgf.cm, 22 ft.lbf)
with SST
27 N.m (275 kgf.cm, 20 ft.lbf)
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.
HINT:
- Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
- Make sure SST and wrench are connected in a straight line.
g. Connect the connector to the fuel pump.
3. INSTALL COVER SUB-ASSEMBLY (for Bank 1)
a. Attach the 5 claws and install the engine cover LH and RH to the fuel pump.
4. INSTALL FUEL PUMP ASSEMBLY (for Bank 2)
HINT: The installation procedures are the same as the bank 1 side.
5. INSTALL NO.2 FUEL PIPE SUB-ASSEMBLY
HINT: The installation procedures are the same as the No.3 fuel pipe sub-assembly.
6. INSTALL COVER SUB-ASSEMBLY (for Bank 2)
HINT: The installation procedures are the same as the bank 1 side.
7. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
a. Install the fuel pressure pulsation damper assembly.
8. INSTALL INTAKE MANIFOLD
a. Install the intake manifold assembly.
9. ADD ENGINE COOLANT
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable to the negative (-) battery terminal.
12. ADD ENGINE COOLANT
13. CHECK FOR ENGINE COOLANT LEAKS
14. CHECK FOR FUEL LEAKS