High Pressure Fuel Pump and Fuel Hose

HIGH PRESSURE FUEL PUMP AND FUEL HOSE


Removal and Installation


REMOVAL

WARNING:
- 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. Testing and Inspection.
2. Remove intake manifold. Exploded View.
3. Disconnect harness connector from high pressure fuel pump.
4. Remove acoustic absorbent. Exploded View.





5. Remove fuel feed tube (1) and 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. Remove fuel hose protector.





8. Disconnect low pressure sensor harness connector (B).
9. Remove quick connector cap from quick connector.
10. Remove fuel hose assembly from fuel hose clamp.
11. Disconnect quick connector (A) with the following procedure.





a. Quick connector (1) can be disconnected when the tabs (F) are completely depressed. Never twist it more than necessary.

B : Connection (Cross-section)
D : To under floor fuel line
E : To fuel tank
G : Disconnection

b. If quick connector and fuel tube on sender unit are stuck, push and pull several times until they move, and pull out.

CAUTION:
- Keep resin tube away from heat. Be especially careful when welding near the resin tube.
- Keep parts away from heat source. Especially, be careful when welding is performed around them.
- Never bend or twist resin tube during installation and disconnection.
- Prevent acid liquid such as battery electrolyte, etc. from getting on resin tube.
- Never remove the remaining retainer (2) on hard tube (or the equivalent) (A) except when resin tube or retainer is replaced.
- When resin tube or hard tube (or the equivalent) is replaced, also replace retainer with new one.

Retainer color : Green





- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or a similar item.
12. Remove fuel pressure sensor assembly.

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.
13. Remove fuel hose assembly.
14. Remove harness clip and bracket mounting bolt.

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:
- 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 front cover. Never decenter or twist it.
2. Install fuel hose assembly.





- Temporarily tighten mounting bolts (A) as shown in the figure.

Arrow :Engine front

3. Install high pressure fuel pump and lifter to front cover.

CAUTION:
After removing lifter, replace lifter with a new one.
4. Connect fuel hose and fuel feed tube to high pressure fuel pump.

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 hose contact fuel pump.
5. Install acoustic absorbent. Exploded View.
6. Tighten mounting bolts that are temporarily tightened in step 2.
7. Connect harness connector to high pressure fuel pump.
8. Install connector protector.
9. Note the following, and connect quick connector to install fuel feed hose.
a. Align the connector with the tube, then insert the connector straight into the tube until a click sound is heard.
b. After connecting, check that the connection is secure by following method.
- Visually confirm that the two retainer tabs are connected to the connector.
- Pull the tube and the connector to check they are securely connected.





c. Install quick connector cap (3) to quick connector connection.

1 : Centralized under-floor piping
2 : Fuel feed hose
B : Under view

- Install quick connector cap with arrow (A) on surface facing in direction of quick connector (fuel feed hose side).

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.
10. Install in the reverse order of removal after this step.