INSTALLATION
CAUTION / NOTICE / HINT
NOTICE:
This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.
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PROCEDURE
1. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY
NOTICE:
When replacing the fuel pump assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.
HINT:
Perform "Inspection After Repair" after replacing the fuel pump assembly.
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(a) Turn the crankshaft pulley until the flat of the No. 2 camshaft faces the fuel pump lifter assembly. HINT: This prevents the No. 2 camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly. |
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(b) Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam. |
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(c) Apply engine oil to the fuel pump lifter assembly.
(d) Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.
(e) Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly. |
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(f) Set the fuel pump lifter assembly on the fuel pump lifter guide as shown in the illustration.
HINT:
Align the stopper key of the fuel pump lifter assembly with the key groove of the fuel pump lifter guide.
(g) Apply engine oil to a new O-ring and install it to the fuel pump assembly.
NOTICE:
Do not damage the O-ring.
(h) Set the fuel pump flange and fuel pump assembly on the cylinder head cover sub-assembly as shown in the illustration. |
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(i) Temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement.
2. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
NOTICE:
Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly.
(a) Temporarily install the bolt.
(b) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel delivery pipe and tighten the union nut by hand.
(c) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.
3. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY
(a) Tighten the 2 bolts.
Torque:
28.5 N·m {291 kgf·cm, 21 ft·lbf}
(b) Connect the fuel pump assembly connector.
4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) for EGR Valve Bracket Connection Type:
(1) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.
*a | 17 mm Union Nut Wrench |
*b | Torque Wrench Fulcrum Length |
Union Nut | |
Bolt |
Torque:
Specified tightening torque :
35 N·m {357 kgf·cm, 26 ft·lbf}
NOTICE:
Do not adjust the torque in the loosening direction.
HINT:
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(2) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.
Torque:
Specified tightening torque :
35 N·m {357 kgf·cm, 26 ft·lbf}
NOTICE:
Do not adjust the torque in the loosening direction.
HINT:
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(3) Using an 8 mm socket wrench, tighten the bolt.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(b) for Cylinder Head Cover Sub-assembly Connection Type:
(1) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.
*a | 17 mm Union Nut Wrench |
*b | Torque Wrench Fulcrum Length |
Union Nut | |
Bolt |
Torque:
Specified tightening torque :
35 N·m {357 kgf·cm, 26 ft·lbf}
NOTICE:
Do not adjust the torque in the loosening direction.
HINT:
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(2) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.
Torque:
Specified tightening torque :
35 N·m {357 kgf·cm, 26 ft·lbf}
NOTICE:
Do not adjust the torque in the loosening direction.
HINT:
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(3) Using an 8 mm socket wrench, tighten the bolt.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(c) Connect the ignition coil connector.
5. INSTALL NO. 2 WATER BY-PASS PIPE
(a) Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B). | |
(b) Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).
(c) Tighten the bolt (B).
Torque:
21 N·m {214 kgf·cm, 15 ft·lbf}
(d) Using the 8 mm socket wrench, tighten the 2 bolts (A).
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(e) Connect the No. 8 water by-pass hose to the No. 2 water by-pass pipe and slide the clip to secure it. HINT: Engage the clip within the area shown in the illustration. |
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(f) Engage the clamp to connect the HV air conditioning wire.
6. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube sub-assembly to the fuel pump assembly and fuel delivery pipe sub-assembly.
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(b) Install the fuel pipe clamp to the fuel tube connector.
7. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
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8. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
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9. INSPECT FOR FUEL LEAK
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10. PERFORM INITIALIZATION
(a) Perform "Inspection After Repair" after replacing the fuel pump assembly.
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