Fuel Pump: Service and Repair

OVERHAUL







IMPORTANT POINTS - REMOVING

1. TURN THE STARTER SWITCH TO THE LOCK POSITION

WARNING: The fuel in the common rail may have a high temperature (approx. 100 °C {212 °F}) immediately after driving. Perform the operation after the engine cools off because there is a danger of fire or burning.







2. REMOVE THE FUEL SUPPLY PUMP
1. Disconnect the fuel lines, oil lines and harness coupler.







2. Turn the flywheel clockwise in the engine direction and align the No.1 cylinder mark to the pointer in the flywheel housing inspection opening.







3. Remove the four bolts of the cover timer.
4. Remove the supply pump by aligning the pump with the helical angle of the gear and twisting the pump in an anti-clockwise direction.
5. Remove the O-ring of the cover timer.
6. Remove the drive gear of the supply pump.
7. Remove the two bolts.
8. Remove the O-ring of the supply pump.







IMPORTANT POINTS - ON - VEHICLE INSPECTION

1. INSPECT THE SUCTION CONTROL VALVE (SCV) AND FUEL TEMPERATURE SENSOR.
1. Measure the resistance between terminals. If not standard value, replace supply pump assembly.

Standard:
SCV 1.6 - 2.6 ohms at 20 °C {68 °F}
Fuel temperature sensor 2.45 kohms at 20 °C {68 °F}
1.15 kohms at 40 °C {104 °F}
584 ohms at 60 °C {140 °F}
318 ohms at 80 °C {176 °F}

NOTICE: If SCV and fuel temperature sensor need replacements, they should be serviced by Denso service dealer.







IMPORTANT POINTS - INSTALLATION

1. INSTALL THE FUEL SUPPLY PUMP.
1. Turn the flywheel clockwise in the engine direction so the engraving of the cylinder is aligned with the pointer in the flywheel housing inspection opening.

NOTICE:
- Make sure that the No.1 cylinder is positioned at the top dead center point of the compression stroke.







2. Install the O-ring to the supply pump.
3. Install the supply pump with 2 bolts to the timer case.

Tightening Torque: 28.5 N.m {2.9 kgf.m, 21 ft.lbf}

4. Install the drive gear assy to the supply pump.
5. Match the notch in the timing plate to the match mark of the timer cover.
6. Fit the cover O-ring in the cover O-ring placement grove.
7. Insert the supply pump by aligning the pump with the helical angle of the gear and twisting the pump in a clockwise direction.












8. In this condition, remove the plug of the bearing cover and insert the SST for confirmation of the position of the notch in the timing plate. When the SST face comes into contact with the boss of the bearing case, the drive gear has been installed in the correct condition. In that case, remove the SST and tighten the four bolts of the body. If the face of the SST does not come into contact with the boss of the bearing case, the drive gear position is not correct and adjustment must be performed again.

Tightening Torque: 28.5 N.m {2.9 kgf.m, 21 ft.lbf}

SST: Guide PIN (99738 - Z5000)

9. Connect the oil line and harness connectors.

2. RESET THE ECU DEFAULT VALUE.

NOTICE: It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service replacement. In addition, the ECU has a function enabling it to learn the performance of the supply pump at the time of ECU service replacement, so ensure sufficient time (several minutes) is available.