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High Pressure Side Fuel Pump: Installation

  1. INSTALL HIGH PRESSURE SIDE FUEL PUMP 
    1. Turn the crankshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.

      HINT:

      When installing the fuel pump using the procedure described above: By not using the crankshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No. 2 fuel pipe later.

    2. Pour 30 cc of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.
      Fig 1: Identifying High Pressure Side Fuel Pump
      G04018693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a coat of engine oil to the pump activation cam and pump lifter part.
      Fig 2: Applying Coat Of Engine Oil To Pump Activation Cam And Pump Lifter Part
      G04018694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new fuel pump insulator to the cylinder head cover. Then pass the 2 stud bolts through the holes of the fuel pump and set it on the insulator.
      NOTE: Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.
    5. Install the union nut of the No. 1 fuel pipe without damaging its seal surface. Tighten the nut as much as possible by hand.
      Fig 3: Identifying Insulator Open Sides Of Metal Eyelets
      G04018695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 2 nuts and tighten them in several passes.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    7. Connect the fuel hose.
      Fig 4: Identifying Fuel Hose
      G04018696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT NO. 2 FUEL PIPE 
    1. Using a 19 mm union nut wrench, connect the fuel pipe.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      Fig 5: Identifying Fuel Pipe
      G04018697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 2 fuel pipe to the delivery pipe with the 2 bolts.

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

    3. Connect the connector to the fuel pump.
      Fig 6: Identifying Fuel Pipe To Delivery Pipe With Bolts
      G04018698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FUEL PRESSURE PULSATION DAMPER (see   5  ) 
  4. INSTALL NO. 1 FUEL PIPE (see   9  ) 
  5. INSTALL INTAKE MANIFOLD (see   11  ) 
  6. REMOVE INTAKE AIR SURGE TANK (see   18  ) 
  7. CONNECT FUEL MAIN TUBE (see   13  ) 
  8. CONNECT VENTILATION HOSE (see   14  ) 
  9. CONNECT UNION TO CHECK VALVE HOSE (see   15  ) 
  10. INSTALL ENGINE REAR COVER (see   16  ) 
  11. CONNECT HEATER WATER OUTLET HOSE (see   17  ) 
  12. CONNECT HEATER WATER INLET HOSE (see   18  ) 
  13. CONNECT WATER BYPASS HOSE (See  ON-VEHICLE INSPECTION  ) 
  14. CONNECT COLD START INJECTOR (see  REMOVAL   ) 
  15. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See  INSTALLATION  ) 
  16. CONNECT NO. 2 VENTILATION HOSE (See  INSTALLATION  ) 
  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  18. ADD ENGINE COOLANT (See  ON-VEHICLE INSPECTION  ) 
  19. CHECK FOR ENGINE COOLANT LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  20. CHECK FOR FUEL LEAKAGE 
    1. Start the engine, and check that there are no fuel leaks after performing maintenance anywhere on the system.
  21. CHECK FOR ENGINE OIL LEAKS 
    1. Start the engine, and check that there are no oil leaks after performing maintenance.
  22. INSTALL V-BANK COVER (See  INSTALLATION  ) 
  23. INSTALL ENGINE ROOM SIDE COVER RH (See  INSTALLATION  ) 
  24. INSTALL COOL AIR INTAKE DUCT SEAL (See  INSTALLATION  ) 
  25. INSTALL ENGINE UNDER COVER (See  INSTALLATION  ) 
  26. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  27. WARM UP ENGINE 
    1. After the engine is warmed up, check that the maintained parts operate normally.
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