Removal And Installation

HIGH PRESSURE FUEL PUMP AND FUEL HOSE


Removal and Installation


REMOVAL

WARNING:
- Be sure to read Precaution For Handling High Pressure Fuel System when working on the high pressure fuel system.
- Put a "CAUTION: FLAMMABLE" sign in the workshop.
- Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
- Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
- To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Release fuel pressure. Testing and Inspection.
2. Remove engine cover. Exploded View.
3. Remove fuel pump connector protector, and remove high pressure fuel pump insulator.





4. Disconnect quick connector (A) with the following procedure.
a. Disconnect fuel feed hose (1) from bracket hose clamp (2).





b. Disengage (A) and pull up (B) the pawl of the fuel feed hose connector retainer (C) to disconnect the fuel feed tube from high pressure fuel pump.

NOTE:
If the fuel feed hose is stuck, hold the fuel pipe by hand and disconnect it by pushing and pulling.

CAUTION:
- Keep parts away from heat source. Especially, be careful when welding is performed around them.
- Never expose parts to battery electrolyte or other acids.
- Never bent or twist connection between quick connector and fuel feed hose (with damper) during installation/removal.
- Pull quick connector holding (D).
- Do not remove the retainer.
- Prepare container and cloth beforehand as fuel will leak out.
- Never pull with lateral force applied. O-ring inside quick connector may be damaged.










- To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags (A), etc. or a similar item.
5. Remove intake manifold. Removal And Installation.
6. Remove fuel feed tube.
7. Remove high pressure fuel pump and lifter.

INSTALLATION

CAUTION:
To install, carefully read the installation procedure to prevent error in generated and damage in parts caused by weight drift.
1. Install high pressure fuel pump with the following procedure.





a. Check the orientation of pump cam from the mounting area
(view arrow) of high pressure fuel pump.
b. Aim pump cam at the BDC area (arrow position).











NOTE:
For BDC area, anywhere within the area indicated by arrow can be accepted.
c. Install O-ring to high pressure fuel pump. When handing new O-ring, paying attention to the following caution items:

CAUTION:
- Handle O-ring with bare hands. Never wear gloves.
- Lubricate O-ring with new engine oil.
- Never clean O-ring with solvent.
- Check that O-ring and its mating part are free of foreign material.
- When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube.
- Insert new O-ring straight into fuel rail. Never decenter or twist it.
d. Install high pressure fuel pump lifter.
e. Apply oil to the fitting area of high pressure fuel pump O-ring and cam shaft bracket side to install high pressure fuel pump.
- After temporary tightening a bolt, tighten a bolt by right and left alternation 1 round till pump flange sitting to rocker cover.
- After a pump flange sitting, tighten the bolts to the specified torque.
2. Connect fuel feed hose with the following procedure, and them install the fuel feed hose.
a. Check no foreign substances are deposited in and around matching pipe and quick connector, and no damage on them.
b. Quick connector shall be inserted gradually, aligning with the axis of the matching pipe.











c. Insert the retainer until it clicks and check the retainer is locked.
After insertion, pull the connector and check that the connector is locked.

CAUTION:
If retainer cannot be installed smoothly, quick connector may be have not been installed correctly. Check connection again.
d. After attaching the quick connector and fix the hose to the clamp.
3. Install the fuel tube with the following procedure.











a. Temporarily tighten flare nut (A) and (B) of fuel tube (3) until seated.

CAUTION:
When temporarily tightening flare nut, place pipe in the center of the nut inner diameter.
b. Temporarily tighten bolt (4) until the seat of bracket is seated.
c. Tighten flare nut (A) and (B) in alphabetical order.
d. Tighten bolt (2).

CAUTION:
- Never reuse fuel tube.
- Never use fuel tube if its terminal tip is damaged.
- Observe the tightening order and the tightening torque.
4. Install in the reverse order of removal after this step.