3.
Remove the high pressure fuel pipe (B) connecting the high pressure fuel pump with the common rail.
Common Rail Fuel Injection System operates with extremely high pressure [approximately 1,600 bar (160 MPa / 23,206 psi)], so never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Keep cleanly the parts and the working area.
Pay attention to a foreign substance.
Just before installing injector, tube or hose, remove the protect-cap attached on them.
Do not remove injector except for special case.
When installing Injector
- Wash the contact area of the injector and replace the washer (gasket) with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
When installing High Pressure Fuel Pipe
- Do not use again the used high pressure fuel pipe.
- Install the flange nut correctly.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
Disconnect the fuel pressure regulator valve connector (A).
Remove the high pressure fuel pipe (B) connecting the high pressure fuel pump with the common rail.
Remove the oil gage guide.
Install the jack under the RH side of the engine.
Remove the engine support bracket.
Tightening torque
Nut (D) : 63.8 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
Bolt (B), Nut (C) : 49.1 ~ 63.8 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
Remove the engine mounting insulator (B).
Disconnect the fuel feed tube (A) and the fuel return tube (B).
Unscrew the three high pressure fuel pump mounting bolts (C).
Remove the drive belt (Refer to "TIMING SYSTEM" in "EM" group).
Turn the crankshaft pulley and align its groove with timing mark "T" of the timing chain cover.
(NO.1 cylinder compression TDC position.)
Remove the idler (A) and the timing chain cover plug (B).
Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
Install the high pressure fuel pump sprocket stopper (A) (SST No.: 09331-2A010) with rotating it clockwise.
Lift the RH side of the engine with a jack.
Install the high pressure fuel pump remover (SST No.:09331-2A010) (A) with three mounting bolts (B).
Fix the high pressure fuel pump remover (SST No.:09331-2A010) (A) and sprocket stopper (C) with two fixing bolts (D).
Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:09331-2A010) (A) clockwise till the high pressure fuel pump is pushed out.
Installation is reverse of removal.
When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool (Refer to below table).
Item | Dimension | SST No. |
Flange Nut (HP Pump Side) | 14 mm (0.551 in) | 09314-27110 |
Flange Nut (Common Rail Side) | 17 mm (0.669 in) | 09314-27120 |
High pressure fuel pump installation bolts:
19.6 ~ 25.5 N.m (2.0 ~ 2.6 kgf.m, 14.5 ~ 18.8 lb-ft)
High pressure fuel pipe installation nut:
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 20.1 lb-ft)
After removing or replacing the part below, bleed air in low pressure fuel circuit (Refer to "Bleeding air in low pressure fuel circuit" in this group).
Fuel Tank
Fuel Sender
Fuel Filter
High Pressure Fuel Pump
Low Pressure Fuel Lines
