High Pressure Oil Pump: Service and Repair

REMOVAL

CAUTION: Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE COOL AIR INTAKE DUCT SEAL
4. REMOVE ENGINE UNDER COVER
5. DRAIN ENGINE COOLANT
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE V-BANK COVER
8. DISCONNECT NO. 2 VENTILATION HOSE
9. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
10. DISCONNECT COLD START INJECTOR
11. DISCONNECT WATER BY-PASS HOSE
12. DISCONNECT HEATER WATER INLET HOSE
13. DISCONNECT HEATER WATER OUTLET HOSE
14. REMOVE ENGINE REAR COVER
15. DISCONNECT FUEL MAIN TUBE
16. DISCONNECT UNION TO CHECK VALVE HOSE
17. DISCONNECT VENTILATION HOSE
18. REMOVE INTAKE AIR SURGE TANK
19. REMOVE INTAKE MANIFOLD
20. DISCONNECT NO. 1 FUEL PIPE
21. REMOVE FUEL PRESSURE PULSATION DAMPER

22. DISCONNECT NO. 2 FUEL PIPE
a. Disconnect the fuel high pressure side fuel pump connector.




b. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.

NOTE:
- There must be absolutely no free play in the union on the fuel pump side.
- If the union on the fuel pump side has free play, replace the fuel pump.




c. Remove the 2 bolts on the delivery pipe side.

NOTE:
- Do not remove the fuel pipe from the delivery pipe. Only remove the 2 bolts.
- If the No. 2 fuel pipe is accidentally removed, replace its O-ring, No. 1 backup ring and No. 2 backup ring.

23. REMOVE HIGH PRESSURE SIDE FUEL PUMP




a. Disconnect the fuel hose.
b. Remove the 2 nuts, fuel pump and fuel pump insulator.

INSTALLATION

1. INSTALL HIGH PRESSURE SIDE FUEL PUMP




a. Turn the crankshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.

HINT: When installing the fuel pump using the procedure described above: By not using the crankshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No. 2 fuel pipe later.

b. Pour 30 cc of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.




c. Apply a coat of engine oil to the pump activation cam and pump lifter part.




d. Install a new fuel pump insulator to the cylinder head cover. Then pass the 2 stud bolts through the holes of the fuel pump and set it on the insulator.

NOTE: Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.

e. Install the union nut of the No. 1 fuel pipe without damaging its seal surface. Tighten the nut as much as possible by hand.

f. Install the 2 nuts and tighten them in several passes.

Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)




g. Connect the fuel hose.

2. CONNECT NO. 2 FUEL PIPE




a. Using a 19 mm union nut wrench, connect the fuel pipe.

Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)




b. Install the No. 2 fuel pipe to the delivery pipe with the 2 bolts.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

c. Connect the connector to the fuel pump.

3. REMOVE FUEL PRESSURE PULSATION DAMPER
4. INSTALL NO. 1 FUEL PIPE
5. INSTALL INTAKE MANIFOLD
6. REMOVE INTAKE AIR SURGE TANK
7. CONNECT FUEL MAIN TUBE
8. CONNECT VENTILATION HOSE
9. CONNECT UNION TO CHECK VALVE HOSE
10. INSTALL ENGINE REAR COVER
11. CONNECT HEATER WATER OUTLET HOSE
12. CONNECT HEATER WATER INLET HOSE
13. CONNECT WATER BY-PASS HOSE
14. CONNECT COLD START INJECTOR
15. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
16. CONNECT NO. 2 VENTILATION HOSE
17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
18. ADD ENGINE COOLANT
19. CHECK FOR ENGINE COOLANT LEAKAGE
20. CHECK FOR FUEL LEAKAGE
a. Start the engine, and check that there are no fuel leaks after performing maintenance anywhere on the system.

21. CHECK FOR ENGINE OIL LEAKS
a. Start the engine, and check that there are no oil leaks after performing maintenance.

22. INSTALL V-BANK COVER
23. INSTALL ENGINE ROOM SIDE COVER RH
24. INSTALL COOL AIR INTAKE DUCT SEAL
25. INSTALL ENGINE UNDER COVER

26. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

27. WARM UP ENGINE
a. After the engine is warmed up, check that the maintained parts operate normally.