High Pressure Fuel Pump Removal and Installation

Flammable - Keep Fire Away

NOTE:


NOTE:
Do not disconnect the water bypass hoses.
Do not bend the water bypass hoses excessively.

3. Intake Manifold Bracket - Remove

5. High Pressure Fuel Pump Cover - Remove


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2.
Remove the high pressure fuel pump cover (B).

6. Fuel Joint Pipe - Remove


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1.
Remove the fuel joint pipe (A).

7. High Pressure Fuel Pump - Remove


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1.
Disconnect the connector (A).
2.
Loosen the bolts (B) alternately, and remove the high pressure fuel pump (C) with the O-ring (D), and the pump lifter (E).





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3.
Remove the fuel feed pipe (A) with the sealing washers (B) from the high pressure fuel pump (C).

8. High Pressure Fuel Pump Cam - Check
1.
Rotate the crankshaft and check the high pressure fuel pump cam (A) for pits, scores, or excessively wear. If needed, replace the intake camshaft.
2.
Install the pump lifter (A) to the high pressure fuel pump cam.
3.
Set the gauge (B) on the pump lifter and hold it.
4.
Rotate the crankshaft 720 ° and measure the four cam lobes height. If the cam lobes are excessively worn, replace the intake camshaft.
NOTE: The high pressure fuel pump cam has four cam lobes.
Grade name
Cam Lobe
Height Standard (New)
Except Si
3.0 mm (0.118 in)
Si
3.7 mm (0.146 in)


Flammable - Keep Fire Away

NOTE:

1. Camshaft Timing - Set
1.
Check the position of the cam (A) that drives high pressure fuel pump as shown. If the cam position angle is wrong as shown, rotate the crankshaft to set it.

2. High Pressure Fuel Pump - Install


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1.
Install the fuel feed pipe (A) to the high pressure fuel pump (B) with new sealing washers (C).





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2.
Coat the pump lifter (A), the cam (B), a new O-ring (C), and around the bore of the lifter insert with clean engine oil.
3.
Install the pump lifter and the high pressure fuel pump (D) with the O-ring.
4.
Temporarily tighten the bolts (E) in an alternate pattern until the high pressure fuel pump is in contact with the cylinder head.
NOTE: To prevent the O-ring from damaging, do not use any power tools (pneumatic or electric).
5.
Connect the connector (F).

3. Fuel Joint Pipe - Install


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NOTE: Before you install the fuel joint pipe (A), loosen the high pressure fuel pump mounting bolts (B).
1.
Lubricate the top of the new fuel joint pipe (C) and the threaded area (D) of the fuel rail and the high pressure fuel pump with polyethylene glycol of a new fuel joint pipe kit.
NOTE: Do not reuse the fuel joint pipe.
2.
Tighten the fuel joint pipe nuts (E) by hand until the end of the joint pipe is seated on the fuel rail and the high pressure fuel pump.
3.
Set the fuel joint pipe bracket (F) to the cylinder head, and loosely install the bolt (G).





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4.
Tighten the high pressure fuel pump mounting bolts (A) to the specified torque.
5.
Tighten the fuel joint pipe bracket mounting bolt (B) to the specified torque.
6.
Tighten the fuel joint pipe nut (C) to the specified torque in the numbered sequence shown.
NOTE: A crowfoot-type special tool increases the torque applied by the torque wrench. Refer to Service Precautions for details on how to recalculate the torque wrench setting.

4. High Pressure Fuel Pump Cover - Install


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1.
Install the high pressure fuel pump cover (A).
NOTE: The high pressure fuel pump cover will be reinstalled after the fuel leak check.