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FUEL PUMP (for High Pressure): Installation

  1. INSTALL FUEL PUMP ASSEMBLY 
    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 by following 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: Turning Crankshaft Until Flat Of Cam Is Facing Cylinder Head Cover's Fuel Pump Attachment Hole
      G05287051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a coat of engine oil to the pump activation cam and pump lifter part.
      Fig 2: Identifying Pump Activation Cam And Pump Lifter Part
      G05287052Courtesy 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 them on the insulator.
      NOTE: Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.
      Fig 3: Identifying Metal Eyelets
      G05826627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily install the No.2 fuel pipe sub-assembly to the fuel pump assembly.
      NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
      Fig 4: Locating No.2 Fuel Pipe Sub-Assembly
      G05287054Courtesy 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 5: Locating Fuel Pump Nuts
      G05287055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT NO. 2 FUEL PIPE 
    1. Install the No. 2 fuel pipe to the delivery pipe with the 2 bolts.

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

      Fig 6: Locating No. 2 Fuel Pipe Bolts
      G05826630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 19 mm union nut wrench, connect the fuel pipe.

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

    3. Connect the connector to the fuel pump.
      4. Fig 7: Connecting Fuel Pipe
      G05826428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 FUEL PIPE  (See INSTALLATION  )
  4. INSTALL FUEL PRESSURE PULSATION DAMPER  (See INSTALLATION  )
  5. CONNECT WATER HOSE JOINT  (See INSTALLATION  )
  6. INSTALL INTAKE MANIFOLD  (See INSTALLATION  )
  7. INSTALL INTAKE AIR SURGE TANK  (See INSTALLATION  )
  8. INSTALL COLD START INJECTOR  (See INSTALLATION  )
  9. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY  (See INSTALLATION )
  10. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  (See INSTALLATION )
  11. CONNECT NO. 2 VENTILATION HOSE  (See INSTALLATION )
  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL  (See INSTALLATION )
  13. ADD ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  14. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  15. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION  )
  16. INSPECT FOR OIL LEAK 
  17. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  20. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  21. INSTALL ROOF DRIP SIDE FINISH MOLDING LH 
  22. INSTALL ROOF DRIP SIDE FINISH MOLDING RH 
  23. INSTALL FRONT UPPER FENDER PROTECTOR LH  (See INSTALLATION )
  24. INSTALL FRONT UPPER FENDER PROTECTOR RH 

    HINT:

    Installation procedure of the RH side is the same as that of the LH side.

  25. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  26. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  27. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  28. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  29. CHECK FUNCTION OF THROTTLE WITH MOTOR BODY ASSEMBLY  (See ON-VEHICLE INSPECTION )
  30. PERFORM INITIALIZATION 
    1. Perform initialization (See INITIALIZATION ).

      HINT:

      Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.

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