Engine Mechanical
HIGH PRESSURE FUEL PUMP AND FUEL HOSE
Removal and Installation
REMOVAL
WARNING:
- Be sure to read "Precaution for Handling High Pressure Fuel System" 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. Refer to the following table:
2.Remove intake manifold. Refer to "Removal and Installation" Removal and Installation.
3.Disconnect harness connector from high pressure fuel pump.
4.Remove fuel feed tube (pump side) (1). Refer to "Exploded View" Exploded View.
5.Disconnect fuel feed hose (2) from high pressure fuel pump.
6.Remove high pressure fuel pump and lifter.
CAUTION:
After removing lifter, replace lifter with a new one.
7.Disconnect quick connector (A) with the following procedure.
a.Remove quick connector cap from quick connector connection.
b.With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.
c.Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position.
CAUTION:
Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.
d.Draw and pull out quick connector straight from fuel tube.
CAUTION:
- Pull quick connector holding (A) position as shown in the figure.
- Never pull with lateral force applied. O-ring inside quick connector may be damaged.
- Prepare container and cloth beforehand because fuel will leak out.
- Avoid fire and sparks.
- 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 (with damper) during installation/removal.
- To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags, etc. or a similar item.
8.Disconnect harness connector from low fuel pressure sensor.
9.Remove fuel feed hose.
10.Remove low fuel pressure sensor.
CAUTION:
- Never allow water and foreign materials enter into the connector.
- Never reuse the dropped sensor.
- Carefully handle sensor avoiding shocks.
- Use hex head support installation for removal and installation of sensor.
- The contact surface of gasket must not have any stain or scoring by dust etc.
INSTALLATION
CAUTION:
Do not reuse O-rings or washers.
1.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.
- 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 front cover.
- Insert new O-ring straight into high pressure fuel pump. Never decenter or twist it.
2.Install low fuel pressure sensor.
CAUTION:
Do not reuse copper washer.
3.Install fuel feed hose.
- Temporarily tighten mounting bolt (A) as shown in the figure.
4.Install high pressure fuel pump and lifter to front cover.
CAUTION:
After removing lifter, replace lifter with a new one.
5.Connect fuel feed hose and fuel feed tube (pump side) to high pressure fuel pump. Refer to "Exploded View" Exploded View.
CAUTION:
- Do not reuse copper washer.
- When removing fuel feed tube (pump side), always replace fuel feed tube (bank side) together with fuel feed tube (pump side).
NOTE:
- Never allow the machined edge of the high pressure fuel pump to contact with gasket.
- The gasket contact area must be free of dust and scratches.
- Check that rotation stopper (A) of fuel feed hose contact high pressure fuel pump.
6.Tighten mounting bolts that are temporarily tightened in step 3.
7.Connect harness connector to high pressure fuel pump.
8.Install fuel pump connector protector.
9.Connect harness connector to low fuel pressure sensor.
10.Note the following, and connect quick connector to install fuel feed hose.
a.Check the connection for foreign material and damage.
b.Align center to insert quick connector straightly into fuel tube.
NOTE:
The figure shows engine side as an example.
- Insert fuel tube into quick connector until the top spool on fuel tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end.
CAUTION:
- Hold "A" position in the figure when inserting fuel tube into quick connector.
- Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
- Insert until you hear a "click" sound and actually feel the engagement.
- To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
c.Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding "A" position.
Check it is completely engaged (connected) so that it does not come out from fuel feed tube.
d.Install quick connector cap to quick connector connection.
- Install so that the arrow mark on the side faces up.
CAUTION:
- Check that quick connector and fuel tube are securely fit into quick connector cap installation groove.
- If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly.
Check connection again.
11.Install in the reverse order of removal.
CAUTION:
After checking fuel leakage, maintain ten minutes of idling to bleed the fuel line.