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Installation [08/2015 - ]: Procedure

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  1. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    1. Turn the crankshaft pulley until the flat of the camshaft faces the fuel pump lifter assembly.
      GTY652694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Lifter Guide
      *2 Fuel Pump Lifter Assembly
      *3 Camshaft
      *a Correct
      *b Incorrect

      HINT: 

      This prevents the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly.

    2. Apply engine oil to a new O-ring and install it to the fuel pump assembly.
    3. Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.
      GTY628920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Assembly
      *2 O-ring
      *3 Fuel Pump Lifter Assembly
      *4 Fuel Pump Lifter Guide
      *a Engine Oil Application Area
    4. Install the fuel pump lifter assembly to the fuel pump lifter guide.
    5. Install the fuel pump assembly to the fuel pump lifter guide.
    6. Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam.
      GTY654102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Cover Sub-assembly
      *2 O-ring
      *3 Fuel Pump Spacer Gasket
      *a No. 4 Camshaft Bearing Cap
      *b Pump Drive Cam (Engine Oil Application Area)
      *c Pump Lifter (Engine Oil Application Area)
      *d Knock Pin
      *e Pin Hole
    7. Apply engine oil to the fuel pump lifter assembly.
    8. Apply engine oil to 2 new O-rings and install them to the No. 4 camshaft bearing cap.
    9. Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.
    10. Set the fuel pump assembly on the cylinder head cover sub-assembly.

      HINT: 

      Align the pin holes of the fuel pump lifter guide with the knock pins of the No. 4 camshaft bearing cap.

    11. Temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement.
  2. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    NOTE:
    • There are 2 types of No. 1 fuel pipe sub-assemblies and 2 types of fuel delivery pipe sub-assemblies.
      Specification No. 1 Fuel Pipe Sub-assembly Union Nut Color Fuel Delivery Pipe Sub-assembly
      for Type A Silver w/ Fuel Pipe Support
      for Type B Black w/o Fuel Pipe Support
      GTY829604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
      *1 No. 1 Fuel Pipe Sub-assembly *2 Fuel Delivery Pipe Sub-assembly
      *3 Fuel Pipe Support - -
      *a Union Nut - -
    • For type A parts and for type B parts are not interchangeable. Before installing the No. 1 fuel pipe sub-assembly and fuel delivery pipe sub-assembly, make sure that they are the same type.
    1. Connect the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.
      NOTE:

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

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

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

  3. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 

    HINT: 

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

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Tighten the 2 bolts.

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

    2. Connect the fuel pump assembly connector.
  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe sub-assembly side of the No. 1 fuel pipe sub-assembly.
      GTY631940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Specified tightening torque 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      HINT: 

    2. 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.

      Specified tightening torque 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      HINT: 

  5. CONNECT FUEL TUBE SUB-ASSEMBLY 
    NOTE:

    Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

    1. Connect the fuel tube sub-assembly to the fuel pump assembly.
      1. Align the fuel tube connector with the fuel pipe and push them together. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.
        GTY673206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Tube Connector
        *c Nylon Tube
        *d O-ring
        *e Fuel Pipe
        Push
        Push in
      2. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
  6. INSTALL INTAKE MANIFOLD 

    Refer to INSTALLATION [08/2015 - ]

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [08/2015 - 10/2016] , or refer to INITIALIZATION [10/2016 - 10/2017] , or refer to INITIALIZATION [10/2017 - 09/2020] , or refer to INITIALIZATION [09/2020 - 11/2021] , or refer to INITIALIZATION [11/2021 - 09/2022] , or refer to INITIALIZATION [09/2022 - 10/2023] , or refer to INITIALIZATION [10/2023 - ]

  8. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  9. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing the fuel pump assembly.

      Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

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