Installation [09/2015 - ]: Procedure

HINT: 

Perform "Inspection After Repairs" after replacing the fuel pump assembly (Refer to INITIALIZATION [09/2015 - ] ).

1. Turn the camshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   By not using the camshaft lobe to push up the pump lifter surface, it is easier to install the fuel pump and No. 3 fuel pipe later.

2. Pour 30 cc (1.8 cu. in.) of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.
3. Apply a coat of engine oil to the pump activation cam and pump lifter.

   Courtesy 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

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

5. Temporarily install the fuel pump with the 2 nuts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. Connect the 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 fuel injector as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • Check that there is no foreign matter or damaged areas in the injector's 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 and is not damaged.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Apply engine oil to the O-ring.

   NOTE:

   Make sure there is no gasoline on the O-ring and inside the installation hole.

3. Temporarily install the No. 3 fuel pipe to the delivery pipe with the 2 bolts.
4. Temporarily install the No. 3 fuel pipe sub-assembly to the fuel pump.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.

5. Tighten the 2 bolts in several passes.

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

6. Tighten the 2 nuts in several passes.

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

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

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

   NOTE:

   • There must be absolutely no free play in the union on the fuel pump side. If the union on the fuel pump side has free play, replace the fuel pump.
   • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Refer to PRECAUTION [09/2015 - ] ).
8. Connect the fuel pump connector.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Attach the 5 claws and install the engine cover LH and RH to the fuel pump.

HINT: 

• Perform "Inspection After Repairs" after replacing the fuel pump assembly (Refer to INITIALIZATION [09/2015 - ] ).
• The installation procedures are the same as the bank 1 side.

HINT: 

The installation procedures are the same as the No. 3 fuel pipe sub-assembly.

HINT: 

The installation procedures are the same as the bank 1 side.

(Refer to INSTALLATION [09/2015 - ] )

Refer to PROCEDURE - Step 1