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 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 hose 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).
- Never remove the retainer.
- Prepare a tray and waste beforehand as fuel leaks out.
- Never pull with lateral force applied. O-ring inside quick connector may be damaged.

Retainer color: Red






- To prevent damage to each joint and protect it from the entry of foreign matter, cover the joint with plastic bag (A) or an equivalent.

5.Remove intake manifold. Removal And Installation.
6.Remove fuel tube.
7.Remove fuel rail connector.





8.Remove high pressure fuel pump (1) and lifter.

CAUTION:
To prevent damage to high pressure fuel pump and camshaft bracket, loosen bolt (A) alternately by one turn at a time until the reaction force applied on the high pressure fuel pump disappears.

INSTALLATION


CAUTION:
- Do not reuse O-rings.
- To prevent damage to parts due to generated abnormal stress and eccentric load, always observe the installation procedure.
1.Install high pressure fuel pump according to 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:
- Do not reuse O-ring.
- 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.
- Never damage O-ring with tools and fingernails during the installation. In addition, twisting or stretching O-ring is not allowed. If O-ring is stretched during the installation to high pressure fuel pump, never install high pressure fuel pump immediately.
d.Install high pressure fuel pump lifter.
e.Apply oil to the fitting area of high pressure fuel pump O-ring and camshaft bracket side to install high pressure fuel pump.
f.Install high pressure fuel pump. To prevent damage to high pressure fuel pump and camshaft bracket, the following instructions must be observed.

CAUTION:





- Temporarily tighten bolt (A) by hand. Alternately tighten bolt by one turn at a time until high pressure fuel pump reaches camshaft bracket.





- 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 new fuel rail connector (1).






CAUTION:
- Never reuse fuel rail connector.
- 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.
- Never scratch O-ring with tools or fingernails when installing fuel rail connector.
- Insert new fuel rail connector straight into fuel rail. Never decenter or twist the fuel rail connector during insertion.
4.Install the fuel tube with the following procedure.

CAUTION:
- Never reuse fuel tube.
- Never use fuel tube if its terminal tip is damaged.
- Observe the tightening order and the tightening torque.





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 (4).
5.Install in the reverse order of removal after this step.