RM38T0EC _51 Engine / Hybrid System _144959 M20F-FXS, M20G-FXS FUEL _0604359 FUEL PUMP(for High Pressure) A

M20F-FXS, M20G-FXS FUEL  FUEL PUMP(for High Pressure)  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A498513N01
4.083,0.25 4.833,0.417 0.75,0.167 4.042,0.208 4.875,0.458 0.833,0.25 2.969,0.417 3.552,0.583 0.583,0.167 4,1.083 4.75,1.417 0.75,0.333 3.958,1.042 4.792,1.458 0.833,0.417 2.5,1.417 3.25,1.75 0.75,0.333 2.458,1.375 3.292,1.792 0.833,0.417 2.927,0.375 3.594,0.625 0.667,0.25 1.167,1.583 1.167,1.917 false 1.802,3.521 2.208,3.521 false 2.698,2.229 2.698,2.563 false 3.469,1.167 3.802,1.167 false 5.385,1.542 5.708,1.542 false 5.094,3.271 5.427,3.271 false 5.146,2.135 5.479,2.135 false 5.219,1.854 5.552,1.854 false 5.313,2.75 5.667,2.75 false 6.531,0.292 6.802,0.292 false 6.5,0.74 6.771,0.74 false 4.833,0.333 5,0.333 5,0.333 5.198,0.635 false 3.552,0.5 3.885,0.5 false 6.458,1.156 6.729,1.156 false 4.625,0.75 4.375,0.917 4.375,0.917 4.375,1.083 false 3.75,1.667 3.417,1.5 3.417,1.5 3.25,1.5 false 1.083,1.979 1.365,2.333 0.281,0.354 18 false 9 2.281,3.365 2.656,3.646 0.375,0.281 18 false 10 2.656,2.604 2.938,2.958 0.281,0.354 18 false 8 3.021,1 3.51,1.333 0.49,0.333 18 false 5, 7 6.031,1.385 6.604,1.729 0.573,0.344 18 false 4, 6 5.646,3.104 5.927,3.458 0.281,0.354 18 false 2 5.781,1.979 6.063,2.333 0.281,0.354 18 false 1 5.635,1.729 6.031,1.958 0.396,0.229 10 false ● 5.26,0.667 5.656,0.896 0.396,0.229 10 false x2 5.76,0.125 6.625,0.375 0.865,0.25 18 false 13, 14 6.188,0.594 6.51,0.885 0.323,0.292 18 false 11 4.115,0.25 4.917,0.396 0.802,0.146 8 false 28.5 (291, 21) 2.99,0.417 3.635,0.594 0.646,0.177 8 false 10 (102, 7) 5.698,1.01 6.458,1.313 0.76,0.302 18 false 12, 15 2.542,1.417 3.271,1.573 0.729,0.156 8 false 35 (357, 26) 2.542,1.573 3.281,1.781 0.74,0.208 8 false 30 (306, 22)* 5.49,3.167 5.885,3.396 0.396,0.229 10 false ● 5.729,2.563 6.01,2.917 0.281,0.354 18 false 3 4.042,1.083 4.771,1.24 0.729,0.156 8 false 35 (357, 26) 4.031,1.25 4.771,1.458 0.74,0.208 8 false 30 (306, 22)*

Procedure Part Name Code
Z101186

Z101188

Z101187

1 FUEL PUMP LIFTER ASSEMBLY 23470 (Click here) - -
2 FUEL PUMP SPACER GASKET 23224D - - -
3 FUEL PUMP FLANGE 23191 - - -
4 TEMPORARILY INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY 23100X (Click here) - -
5 TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 23801P (Click here) - -
6 INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY 23100X (Click here) - -
7 INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 23801P (Click here) - -
8 FUEL TUBE SUB-ASSEMBLY 23910A (Click here) - -
9 INTAKE MANIFOLD 17111 - - -
10 EGR VALVE ASSEMBLY 25620 - - -
11 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL - - - -
12 INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL - - - (Click here)
13 INSPECT FOR FUEL LEAK - (Click here) - -
14 INSPECT FOR ENGINE OIL LEAK - (Click here) - -
15 PERFORM INITIALIZATION - - - (Click here)

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) * For use with a union nut wrench
● Non-reusable part - -

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.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


PROCEDURE

Hide 23470 1.INSTALL FUEL PUMP LIFTER ASSEMBLY

Z101186

NOTICE:
·

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

·

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

Click here(Click here)




a.
A467843C02
5.49,1.583 5.875,1.583 true 6.219,0.875 6.479,0.875 true 6.229,1.625 6.615,1.625 true 3.625,1.156 3.781,0.75 3.781,0.75 3.938,0.75 true 3.479,3.083 3.406,3.375 3.406,3.375 3.281,3.375 true 1.115,1.156 1.24,0.865 1.24,0.865 1.448,0.865 true 0.906,2.469 0.781,2.469 false 1.927,2.458 1.802,2.458 false 2.042,3.021 1.917,3.021 false 1.833,2.104 1.99,2.104 false 0.948,2.104 0.823,2.104 false 0.979,3.042 0.844,3.042 true 5.74,0.896 5.906,0.896 true 2.052,2.031 2.333,2.219 0.281,0.188 10 false *1 0.938,2.406 1.167,2.604 0.229,0.198 10 false *2 1.51,0.802 1.75,0.99 0.24,0.188 10 true *3 0.51,3.365 0.771,3.531 0.26,0.167 10 false *a 1.521,3.385 1.771,3.552 0.25,0.167 10 false *b 3.979,0.677 4.219,0.854 0.24,0.177 10 true *c 3.094,3.313 3.406,3.469 0.313,0.156 10 false *d 6.521,0.813 6.74,0.979 0.219,0.167 10 true *e 6.635,1.542 6.844,1.75 0.208,0.208 10 true *f 5.552,0.813 5.76,0.979 0.208,0.167 10 true *g 5.365,1.51 5.531,1.677 0.167,0.167 10 true *h 1.958,2.396 2.156,2.604 0.198,0.208 10 false *2 2.073,2.958 2.281,3.146 0.208,0.188 10 false *3 1,2.031 1.313,2.188 0.313,0.156 10 false *1 1,2.99 1.219,3.146 0.219,0.156 10 false *3 0.49,0.125 0.75,0.417 0.26,0.292 18 true i 3.24,0.604 3.438,0.854 0.198,0.25 18 true ii 5.427,0.146 6.073,0.375 0.646,0.229 18 true iv, v 2.885,3.229 3.104,3.5 0.219,0.271 18 true iii
*1 Fuel Pump Assembly *2 Fuel Pump Lifter Assembly
*3 Camshaft - -
*a Correct *b Incorrect
*c Pump Drive Cam (Engine Oil Application Area) *d Pump Lifter (Engine Oil Application Area)
*e Fuel Pump Lifter Assembly (Engine Oil Application Area) *f Fuel Pump Lifter Guide (Engine Oil Application Area)
*g Stopper key *h Key Groove


i.

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.



ii.

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


iii.

Apply engine oil to the fuel pump lifter assembly.


iv.

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


v.

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.




Hide 23224D 2.INSTALL FUEL PUMP SPACER GASKET

Hide 23191 3.SET FUEL PUMP FLANGE

a.
A522586


Hide 23100X 4.TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

a.
A498519N01
0.406,0.052 0.688,0.406 0.281,0.354 18 false i 3.51,0.031 4,0.313 0.49,0.281 18 true ii, iii

i.

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

NOTICE:

Do not damage the O-ring.



ii.

Set the fuel pump assembly on the cylinder head cover sub-assembly.


iii.

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



Hide 23801P 5.TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Z101186

NOTICE:

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



a.
A498520N01
1.542,1.417 1.677,1.677 0.135,0.26 18 true i 2.177,0.438 2.375,0.708 0.198,0.271 18 true ii 3.823,0.052 4.052,0.292 0.229,0.24 18 true iii

i.

Connect the No. 1 fuel pipe sub-assembly to the fuel delivery pipe and tighten the union nut by hand.


ii.

Connect the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.


iii.

Temporarily install the bolt.



Hide 23100X 6.INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

a.
A498521N01
0.365,0.031 0.646,0.385 0.281,0.354 18 false i 3.688,0.063 3.969,0.417 0.281,0.354 18 false ii

i.

Tighten the 2 bolts.

Torque:
28.5 N*m (291 kgf*cm, 21 ft.*lbf)


ii.

Connect the fuel pump assembly connector.



Hide 23801P 7.INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

a.
A498522C01
6,0.75 6.083,0.5 6.083,0.5 6.25,0.5 false 1.406,1.49 1.594,1.771 0.188,0.281 18 true i 2.052,0.479 2.24,0.76 0.188,0.281 18 true ii 0.385,1.948 0.625,2.219 0.24,0.271 18 true iii 3.458,2 3.698,2.271 0.24,0.271 18 true iv 5.073,0.427 5.26,0.708 0.188,0.281 10 false *b 6.271,0.406 6.458,0.688 0.188,0.281 10 false *a
*a 17 mm Union Nut Wrench *b Torque Wrench Fulcrum Length


i.

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 hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

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)




ii.

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 hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

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)




iii.

Using an 8 mm socket wrench, tighten the bolt.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


iv.

Connect the ignition coil assembly connector.



Hide 23910A 8.CONNECT FUEL TUBE SUB-ASSEMBLY

a.
A498514N02
0.438,0.073 0.719,0.427 0.281,0.354 18 false i

i.

Connect the fuel tube sub-assembly to the fuel pump assembly.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (FUEL)>FUEL SYSTEM>PRECAUTION



Hide 12. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART


Hide 15.PERFORM INITIALIZATION

a.

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

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION