Installation [04/2013 - 08/2015]: Procedure

1. Install a new O-ring, new No. 1 back-up ring, new No. 2 back-up ring, new No. 3 back-up ring and new E-ring to the No. 2 fuel pipe sub-assembly as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Back-up Ring	*2	No. 2 Back-up Ring
   *3	No. 3 Back-up Ring	*4	O-ring
   *5	E-ring	-	-
   *a	Alignment Opening	*b	Overlapped
   *c	Stretched	*d	Correct
   *e	Incorrect	-	-

   NOTE:

   • Check that there is no foreign matter or damage on the O-ring groove of the No. 2 fuel pipe sub-assembly.
   • Check that the No. 1 back-up ring and No. 2 back-up ring are installed in the correct direction.
   • Make sure that the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and O-ring are installed in the correct order.
   • Check that the alignment openings of the back-up 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 and is not damaged.
   • Check that the No. 2 fuel pipe sub-assembly installation end is not contaminated with foreign matter and is not damaged.
2. Apply gasoline to the O-ring and connect the No. 2 fuel pipe sub-assembly to the fuel delivery pipe sub-assembly.
   NOTE:

   • Do not install the No. 2 fuel pipe sub-assembly at an angle.
   • Do not install the bolt at this time.

HINT: 

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

Refer to INITIALIZATION [04/2013 - 08/2015]

1. Turn the crankshaft pulley until the flat of the cam lobe faces the cylinder head cover fuel pump assembly installation hole as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Fuel Pump Assembly
   *a	Cam Lobe
   *b	Oil Collector
   *c	Correct
   *d	Incorrect

   HINT: 

   When installing the fuel pump assembly by following the procedure described above: By not using the cam lobe nose to push up the pump activation surface, it is easier to install the fuel pump assembly and No. 2 fuel pipe sub-assembly later.

2. Pour 30 cc (1.8 cu in.) of engine oil through the cylinder head cover sub-assembly fuel pump assembly installation hole into the cylinder head cover sub-assembly oil collector.
3. Apply a coat of engine oil to the cam lobe and pump lifter.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Cam Lobe
   *b	Pump Lifter

4. Install a new fuel pump insulator to the cylinder head cover sub-assembly. Then pass the 2 stud bolts through the holes of the fuel pump assembly and fuel pump insulator.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Metal Eyelets
   	Stud Bolt

   NOTE:

   Install the fuel pump insulator so that the open sides of the metal eyelets are facing outward as shown in the illustration.

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 No. 2 fuel pipe sub-assembly when temporarily installing the No. 2 fuel pipe sub-assembly.

   Fig 1: Installing No 2 Fuel Pipe Sub-Assembly To Fuel Pump Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the 2 nuts and tighten them in several steps.

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

1. Install the No. 2 fuel pipe sub-assembly to the fuel delivery pipe sub-assembly with the 2 bolts.

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

2. Using a 19 mm union nut wrench, connect the No. 2 fuel pipe sub-assembly.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	19 mm Union Nut Wrench

   HINT: 

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

   Refer to PRECAUTION [04/2013 - 08/2015]

3. Connect the fuel pump assembly connector.

1. Install the No. 1 fuel pipe sub-assembly with the 2 bolts.

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

2. Connect the No. 2 fuel hose to the fuel pump assembly and slide the clip to secure it.
3. Connect the No. 1 fuel hose to the fuel relief valve assembly and slide the clip to secure it.
4. Connect the No. 3 fuel hose to the No. 1 fuel pipe sub-assembly and slide the clip to secure it.

See step  1

1. Connect the No. 8 water by-pass hose and No. 9 water by-pass hose to the No. 3 water by-pass pipe and slide the 2 clips to secure them.
2. Install the No. 3 water by-pass pipe to the camshaft housing sub-assembly RH with the bolt.

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

3. Engage the wire harness clamp to the No. 3 water by-pass pipe.
4. Connect the inlet heater water hose A and outlet heater water hose A to the No. 3 water by-pass pipe and slide the 2 clips to secure them.

Refer to INSTALLATION [04/2013 - 08/2015]

Refer to PROCEDURE - Step 1

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

   Refer to INITIALIZATION [04/2013 - 08/2015]