FUEL PUMP (for High Pressure): Installation

1. Rotate the crankshaft until the base circle of the fuel pump cam is facing the hole in the cylinder head cover as shown in the illustration.

   HINT.

   Setting the cam in this position does not compress the fuel pump plunger, making it easier to install the fuel pump assembly and No. 3 fuel pipe sub-assembly later.

2. Pour 30 cm³ (1 8 cu in) of engine oil through the hole in the cylinder head cover into the cylinder head oil collector.
   Fig 1: Identifying Camshaft And Oil Collector

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3. Apply a coat of engine oil to the fuel pump activation cam and pump plunger.
   Fig 2: Identifying Fuel Pump Activation Cam And Pump Plunger

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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 assembly and set them on the fuel pump insulator
   NOTE: Install the fuel pump insulator so that the open sides of the metal eyelets are facing outward as shown in the illustration.
   Fig 3: Identifying Metal Eyelets

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5. Temporarily install the 2 nuts and fuel pump assembly
   Fig 4: Locating Fuel Pump Assembly Nuts

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6. Connect the fuel hose.
Fig 5: Locating Fuel Hose
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1. Install a new O-ring, new backup rings (No. 1 and No 2) and new E-ring to the No. 3 fuel pipe sub-assembly as shown in the illustration
   Fig 6: Identifying O-Ring, Backup Rings And E-Ring

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   NOTE:

   • Check that there is no foreign matter or damaged areas in the No. 3 fuel pipe sub-assembly O-ring groove.
   • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
   • Make sure that the backup rings and O-ring are installed in the correct order.
   • Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
   • After installing the O-ring, check that it is not contaminated with foreign matter or damaged.
2. Temporarily install the No. 3 fuel pipe sub-assembly to the delivery pipe with the 2 bolts.
   Fig 7: Locating Fuel Pipe Bolts

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3. Temporarily install the No. 3 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 No. 3 fuel pipe sub-assembly.
   Fig 8: Locating Fuel Pipe

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4. Install the No 3 fuel pipe to the delivery pipe with the 2 bolts and tighten them in several passes.

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

   Fig 9: Locating Fuel Pipe Bolts

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5. Install the fuel pump assembly with the 2 nuts and tighten them in several passes.

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

   Fig 10: Locating Fuel Pump Assembly Nuts

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6. Using a 19 mm union nut wrench, tighten the union nut.

   Torque: without a union nut wrench 

   30 N*m (306 kgf*cm, 22 ft.*lbf) 

   with a union nut wrench 

   27 N*m (275 kgf*cm, 20 ft.*lbf) 

   NOTE: There must be absolutely no free play in the union on the fuel pump assembly side. If the union on the fuel pump assembly side has free play, replace the fuel pump assembly.

   HINT:

   • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.)
   • Make sure that the union nut wrench and torque wrench are connected in a straight line.
7. Connect the connector to the fuel pump assembly.
Fig 11: Tightening Union Nut
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1. Attach the 5 claws and install the engine covers LH and RH to the fuel pump assembly.
Fig 12: Identifying Engine Covers
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HINT

Use the same procedure as for the bank 1 side.

1. Install a new O-ring, new backup rings (No 1 and No 2) and a new E-ring to the No 2 fuel pipe sub-assembly as shown in the illustration.
   Fig 13: Identifying O-Ring, Backup Rings And E-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check that there is no foreign matter or damaged areas in the injector O-ring groove.
   • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
   • Make sure that the backup rings and O-ring are installed in the correct order.
   • Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
   • After installing the O-ring, check that it is not contaminated with foreign matter or damaged.
2. Temporarily install the No. 2 fuel pipe to the cylinder head cover with the bolt.
   Fig 14: Locating Fuel Pipe Bolt

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3. Temporarily install the No 2 fuel pipe sub-assembly to the delivery pipe with the 2 bolts.
   Fig 15: Locating Fuel Pipe Bolts

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4. 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 No. 2 fuel pipe sub-assembly.
   Fig 16: Locating Fuel Pipe

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5. Install the No 2 fuel pipe sub-assembly to the delivery pipe with the 2 bolts and tighten them in several passes.

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

   Fig 17: Locating Fuel Pipe Bolts

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6. Install the fuel pump assembly with the 2 nuts and tighten them in several passes

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

   Fig 18: Locating Fuel Pump Assembly Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a 19 mm union nut wrench, tighten the union nut

   Torque: without a union nut wrench 

   30 N*m (306 kgf*cm, 22 ft.*lbf) 

   with a union nut wrench 

   27 N*m (275 kgf*cm, 20 ft.*lbf) 

   NOTE: There must be absolutely no free play in the union on the fuel pump assembly side. If the union on the fuel pump assembly side has free play, replace the fuel pump assembly.

   HINT.

   • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.).
   • Make sure that the union nut wrench and torque wrench are connected in a straight line
   Fig 19: Tightening Union Nut

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8. Install the No. 2 fuel pipe sub-assembly to the cylinder head cover with the bolt.

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

9. Connect the connector to the fuel pump assembly

Fig 20: Locating Fuel Pipe Bolt

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HINT.

Use the same procedure as for the bank 1 side

1. Install the fuel pressure pulsation damper assembly and No 1 fuel pipe sub-assembly (See INSTALLATION ).