Components and components location

Fuel pressure test

1.

Release the residual pressure in fuel line. (Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line") • When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.

2.

Install the Special Service Tool (SST). (1) Disconnect the fuel feed tube from the delivery pipe. • There may be some residual pressure even after “Release Residual Pressure in Fuel Line” work, so cover the hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any fuel connection. (2) Install the special service tool for measuring the fuel pressure in between the fuel feed tube and the fuel delivery pipe (Refer to the figure below).

4.

Measure Fuel Pressure. (1) Start the engine and measure the fuel pressure at idle. Fuel Pressure : 353 - 500 kPa (3.6 - 5.1 kgf/cm², 51.2 - 72.5 psi) • If the fuel pressure differs from the standard value, repair or replace the related part (Refer to the table below). Fuel Pressure Cause Related Part Too Low Fuel filter clogged Fuel Filter Fuel leakage Fuel Pressure Regulator Too High Fuel pressure regulator valve stuck Fuel Pressure Regulator (2) Stop the engine, and then check for the change in the fuel pressure gauge reading. Standard Value : The gauge reading should hold for about 5 minutes after the engine stops • If the gauge reading should not be held, repair or replace the related part (Refer to the table below). Fuel Pressure (After Engine Stops) Cause Related Part Fuel Pressure Drops Slowly Leakage on injector Injector Fuel Pressure Drops Immediately Check valve of fuel pump stuck open Fuel Pump (3) Turn the ignition switch OFF.

5.

Release the residual pressure in fuel line. (Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line") • When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.

Release residual pressure in fuel line

• There may be some residual pressure even after "Release Residual Pressure in Fuel Line" work, so cover the hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any fuel connection.

7.	Delete the Diagnostic Trouble Code (DTC) related the fuel pump fuse with the diagnostic tool. • When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.

Fuel Tank

Repair procedures

12.	Remove the fuel tank band (A). Tightening torque : 39.2 - 54.0 N.m (4.0 - 5.5 kgf.m, 28.9 - 39.8 lb-ft) • Support the jack to avoid damaging the fuel tank.

Fuel Pump

Repair procedures

7.	Remove the locking ring (A) by using the special service tool [No. : 09310-B8100]. • When removing the locking ring, be careful not to damage the fuel tank and fuel pump. • When removing the locking ring, press the upper area with hand and rotate the wrench counter clockwise.

1.	Install in the reverse order of removal. • Be careful of fuel pump direction when installing. (Refer to the groove in the fuel tank)

Fuel Filter

Repair procedures

Fuel Pump Motor

Repair procedures

Fuel Sender Assembly

Repair procedures

Fuel Pressure Regulator

Repair procedures

Fuel Line

Repair procedures

5.

Disconnect the fuel feed tube quick-connector (A). • Open the clamp cover (A) before disconnecting the quick-connector. (If the clip is applied) • When removing the quick-connnector with the clip removing tool (A), be careful not to damage the plastic clip (B). • If the clip is damaged, fuel line leakage may occur due to poor connection.

Accelerator Pedal

Repair procedures

Delivery Pipe

Repair procedures

• In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

2.	Turn the ignition switch OFF and disconnect the battery negative (-) cable. • When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.

1.

Install in the reverse order of removal. • Do not reuse the high pressure fuel pipe. • Be careful not to deform the shape of the high pressure fuel pipe. • Do not tilt the torque wrench when tightening the nut. • Install the component to the specified torques. • Check the fuel leakage after installing the high pressure fuel pipe. • Use the special service tool [SST No. : 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe. • Do not reuse the mounting bolt. • Do not reuse the injector fixed clip. • Do not reuse the combustion seal (A). • Be careful not to apply oil to the combustion seal. • Do not reuse the O-ring (A), support disc (B), rubber washer (C). • When replacing the rubber washer, the steal plate part should be faced the cylinder installation part and the rubber plate part should be faced the injector body part. • Apply engine oil to the injector O-ring. • When inserting the injector, be careful not to damage the injector tip • Do not reuse the high fuel pipe.

High Pressure Fuel Pump

Repair procedures

• In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

2.	Turn the ignition switch OFF and disconnect the battery negative (-) cable. • When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.

5.

Disconnect the fuel feed tube quick-connector (B). • Open the clamp cover (A) before disconnecting the quick-connector. (If the clip is applied) • When removing the quick-connnector with the clip removing tool (A), be careful not to damage the plastic clip (B). • If the clip is damaged, fuel line leakage may occur due to poor connection.

1.

Install in the reverse order of removal. • Unscrew in turn the mounting bolt (A) in small steps (0.5 turns). If one of the two bolts is fully unscrewed while the other is installed, the housing surface of the cylinder head may get broken due to the tension on the pump spring. • Do not reuse the high pressure fuel pipe. • Be careful not to deform the shape of the high pressure fuel pipe. • Do not tilt the torque wrench when tightening the nut. • Install the component to the specified torques. • Check the fuel leakage after installing the high pressure fuel pipe. • Use the special service tool [SST No. : 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe. • Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may break due to the tension on the pump spring. • Do not reuse the bolt. • Install the component to the specified torques. • Note that internal damage may occur when the component is dropped. In this case, use it after inspecting. • Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove on the location where the protrusion (C) is installed.