INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY

NOTICE:

When replacing the fuel pump assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

HINT:

Perform "Inspection After Repair" after replacing the fuel pump assembly.

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(a) Turn the crankshaft pulley until the flat of the camshaft faces the fuel pump lifter assembly. HINT: This prevents the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly.

*1 Fuel Pump Assembly *2 Fuel Pump Lifter Assembly *3 No. 2 Camshaft *a Correct *b Incorrect

(b) Apply 30 cc (1.8 cu.in.) of engine oil to the pump drive cam.

*1 Cylinder Head Cover Sub-assembly *2 Fuel Pump Spacer Gasket *a Pump Drive Cam (Engine Oil Application Area) *b Fuel Pump Lifter Assembly (Engine Oil Application Area)

(c) Apply engine oil to the fuel pump lifter assembly.

(d) Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.

(e) Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.

*a Fuel Pump Lifter Assembly (Engine Oil Application Area) *b Fuel Pump Lifter Guide (Engine Oil Application Area) *c Stopper Key *d Key Groove

(f) Set the fuel pump lifter assembly on the fuel pump lifter guide as shown in the illustration.

HINT:

Align the stopper key of the fuel pump lifter assembly with the key groove of the fuel pump lifter guide.

(g) Apply engine oil to a new O-ring and install it to the fuel pump assembly.

NOTICE:

Do not damage the O-ring.

(h) Set the fuel pump flange and fuel pump assembly on the cylinder head cover sub-assembly as shown in the illustration.

*1 Fuel Pump Assembly *2 Fuel Pump Flange

(i) Temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement.

2. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

NOTICE:

Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly.

(a) Temporarily install the bolt.

(b) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel delivery pipe and tighten the union nut by hand.

(c) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.

3. INSTALL FUEL PUMP ASSEMBLY

(a) Tighten the 2 bolts.

Torque:

28.5 N·m {291 kgf·cm, 21 ft·lbf}

(b) Connect the connector to the fuel pump assembly.

4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly. Torque: Specified tightening torque : 35 N·m {357 kgf·cm, 26 ft·lbf} NOTICE: Do not adjust the torque in the loosening direction. HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a Torque Wrench Fulcrum Length

(b) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly. Torque: Specified tightening torque : 35 N·m {357 kgf·cm, 26 ft·lbf} NOTICE: Do not adjust the torque in the loosening direction. HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a Torque Wrench Fulcrum Length

(c) Connect the No. 1 fuel pipe sub-assembly to the cylinder head sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Connect the connector to the ignition coil assembly.

5. INSTALL NO. 2 WATER BY-PASS PIPE

(a) Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B).

(b) Temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).

(c) Tighten the bolt (B).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Tighten the 2 bolts (A).

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Connect the No. 8 water by-pass hose to the No. 2 water by-pass pipe, and slide the clip to secure hose. HINT: Attach the clip within the area shown in the illustration.

*a 45° *b Left Side of Vehicle

(f) Attach the clamp and connect the HV air conditioning wire.

6. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel pump assembly and fuel delivery pipe sub-assembly.

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(b) Install the fuel pipe clamp to the fuel tube connector.

7. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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8. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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9. INSTALL BATTERY HOLE COVER

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10. INSTALL REAR NO. 2 FLOOR BOARD

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11. INSTALL DECK BOARD ASSEMBLY

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12. INSPECT FOR FUEL LEAK

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13. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing the fuel pump assembly.

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