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Removal and Installation
 
 
REMOVAL
warning
  • Be sure to read Precaution for Handling High Pressure Fuel SystemPrecaution 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. Refer to Work ProcedureWork Flow.
2. Remove engine cover. Refer to Removal and Installation. (With engine cover models)
3. Remove high pressure fuel pump insulator bracket. Refer to Exploded View. (Without engine cover models)
4. Remove air duct. Refer to Removal and Installation.Removal and Installation
5. Remove battery tray. Refer to Removal and Installation.Removal and Installation
6. Remove high pressure fuel pump insulator.
7. Disconnect quick connector with the following procedure.
  1. Disconnect fuel feed hose from bracket hose clamp .
  2. Disengage and pull up the pawl of the fuel feed hose connector retainer to disconnect the fuel feed hose from high pressure fuel pump.
    noteIf 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 bend or twist connection between quick connector and fuel feed hose during installation/removal.
    • Pull quick connector holding .
    • 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.
    • To prevent damage to each joint and protect it from the entry of foreign matter, cover the joint with plastic bag or an equivalent.
8. Remove intake manifold. Refer to Removal and Installation.
9. Remove high pressure fuel tube.
cautionDo not reuse high pressure fuel tube.
10. Disconnect high pressure fuel pump harness connector from the high pressure fuel pump.
11. Remove high pressure fuel pump and lifter.
caution
  • To prevent damage to high pressure fuel pump and camshaft bracket, loosen bolt alternately by one turn at a time until the reaction force applied on the high pressure fuel pump disappears.
  • Do not reuse O-rings.
 
 
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.
  1. Check the orientation of pump cam from the mounting area (view arrow) of high pressure fuel pump.
  2. Aim pump cam at the BDC area (arrow position).
    : Camshaft (EXH)
    noteFor BDC area, anywhere within the area indicated by arrow can be accepted.
  3. 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.
  4. Lubricate high pressure fuel pump lifter and high pressure fuel pump lifter bore with clean engine oil.
  5. Reinstall the high pressure fuel pump lifter.
    noteWhen installing high pressure fuel pump lifter, note the orientation of protrusion and cutout in camshaft bracket, they should be aligned.
  6. Apply oil to the fitting area of high pressure fuel pump O-ring and camshaft bracket side to install high pressure fuel pump.
  7. Install high pressure fuel pump. To prevent damage to high pressure fuel pump and camshaft bracket, the following instructions must be observed.
    1. Tighten the high pressure fuel pump bolt until it hits the high pressure fuel pump, and then tighten both bolts by 180 degrees.
      : High pressure fuel pump
    2. Temporarily alternately tighten bolt by three turn at time by hand.
      : High pressure fuel pump
    3. While pushing the center of the high pressure fuel pump by hand until it hits the camshaft bracket, tighten the high pressure fuel pump bolt by the following procedure:
      1. Tighten the bolt (1) as shown in the figure (temporarily).
        : 2.0 N·m (0.2 kg-m, 18 in-lb)
        : High pressure fuel pump
      2. Tighten the bolt (2) as shown in the figure (spceified torque).
        : 10.0 N·m (1.0 kg-m, 89 in-lb)
      3. Tighten the bolt (3) as shown in the figure (spceified torque).
        : 10.0 N·m (1.0 kg-m, 89 in-lb)
2. Connect fuel feed hose with the following procedure, and them install the fuel feed hose.
  1. Check no foreign substances are deposited in and around matching pipe and quick connector, and no damage on them.
  2. Quick connector shall be inserted gradually, aligning with the axis of the matching pipe.
  3. Insert the retainer until it clicks and check the retainer is locked. After insertion, pull the connector and check that the connector is locked.
    : Lock position
    : Unlock position
    cautionIf retainer cannot be installed smoothly, quick connector may be have not been installed correctly. Check connection again.
3. Install the fuel tube with the following procedure.
caution
  • When removing fuel tube, always replace fuel rail connector together with fuel tube.
  • Never reuse fuel tube.
  • Never use fuel tube if its terminal tip is damaged.
  • Observe the tightening order and the tightening torque.
  1. Temporarily tighten until the high pressure fuel tube flare nuts and contact the seat.
    cautionWhen temporarily tightening flare nut, place pipe in the center of the nut inner diameter.
  2. Temporarily tighten the high-pressure fuel tube bracket mounting bolt .
  3. Tighten flare nut to the specified torque.
    : 23.0 N·m (2.3 kg-m, 17 ft-lb)
    cautionBefore tightening, check that the tool is attached at a 90° angle to the flare nut when working.
  4. Tighten flare nut to the specified torque.
    : 23.0 N·m (2.3 kg-m, 17 ft-lb)
    cautionBefore tightening, check that the tool is attached at a 90° angle to the flare nut when working.
  5. Again tighten flare nut to the specified torque.
    : 23.0 N·m (2.3 kg-m, 17 ft-lb)
    cautionBefore tightening, check that the tool is attached at a 90° angle to the flare nut when working.
  6. Again tighten flare nut to the specified torque.
    : 23.0 N·m (2.3 kg-m, 17 ft-lb)
    cautionBefore tightening, check that the tool is attached at a 90° angle to the flare nut when working.
  7. Tighten tighten the high-pressure fuel tube bracket mounting bolt specified torque.
    : 25.0 N·m (2.6 kg-m, 18 ft-lb)
4. Install in the reverse order of removal after this step.
cautionAfter checking fuel leakage, maintain ten minutes of idling to bleed the fuel line.