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Installation [08/2023 - ]: Procedure

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  1. INSTALL FUEL PUMP LIFTER ASSEMBLY 
    1. GTY1075250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel (Engine Room Side) Pump Assembly *2 Fuel Pump Lifter Assembly
      *3 Camshaft - -
      *a Correct *b Incorrect
      *c Pump Drive Cam (Engine Oil Application Area) *d Fuel Pump Lifter Assembly (Engine Oil Application Area)
      *e Fuel Pump Lifter Guide (Engine Oil Application Area) *f Stopper Key
      *g Key Groove - -
      1. Turn the crankshaft pulley until the flat of the camshaft faces the fuel pump lifter assembly.

        HINT: 

        This prevents the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel (engine room side) pump assembly.

      2. Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam.
      3. Apply engine oil to the fuel pump lifter assembly.
      4. Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.
      5. Set the fuel pump lifter assembly on the fuel pump lifter guide as shown in the illustration.

        HINT: 

        Align the stopper key of the fuel pump lifter assembly with the key groove of the fuel pump lifter guide.

  2. INSTALL FUEL PUMP SPACER GASKET 
  3. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    NOTE:

    When replacing the fuel (engine room side) pump assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.
    1. GTY1075529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply engine oil to a new O-ring and install it to the fuel (engine room side) pump assembly.
        NOTE:

        Do not damage the O-ring.

      2. Set the fuel pump flange and fuel (engine room side) pump assembly on the No. 4 camshaft bearing cap.
      3. Temporarily install the fuel (engine room side) pump assembly with the 2 bolts, leaving some allowance for left and right movement.
  4. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    NOTE:

    Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly.
    1. GTY1074973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the No. 1 fuel pipe sub-assembly to the fuel delivery pipe and tighten the union nut by hand.
      2. Temporarily install the No. 1 fuel pipe sub-assembly to the fuel (engine room side) pump assembly and tighten the union nut by hand.
      3. Using an 8 mm socket wrench, temporarily install the bolt.
  5. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    1. GTY1075602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Tighten the 2 bolts.

        Torque: 28.5 N.m (291 kgf/cm, 21 ft.lbf) 

      2. Connect the fuel (engine room side) pump assembly connector.
  6. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. GTY1074916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17 mm Union Nut Wrench *b Torque Wrench Fulcrum Length
      1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

        Specified tightening torque 

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

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [10/2022 - ]

        • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
      2. Using a 17 mm union nut wrench, tighten the union nut on the fuel (engine room side) 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: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [10/2022 - ]

        • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
      3. Using an 8 mm socket wrench, tighten the bolt.

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

      4. Connect the ignition coil connector.
  7. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. GTY1076119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tube sub-assembly to the fuel (engine room side) pump assembly and fuel delivery pipe sub-assembly.

        Refer to PRECAUTION [08/2023 - ]

  8. INSTALL FUEL PIPE CLAMP 
  9. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. GTY1075543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45° *b Left Side of Vehicle
      1. Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (A).
      2. Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (B).
      3. Tighten the bolt (A).

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      4. Using an 8 mm socket wrench, tighten the 2 bolts (B).

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

      5. Connect the No. 8 water by-pass hose to the No. 2 water by-pass pipe and slide the clip to secure it.

        HINT: 

        Engage the clip within the area shown in the illustration.

      6. Engage the clamp to connect the HV air conditioning wire.
  10. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [08/2023 - ]

  11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 5

  12. INSTALL BATTERY SERVICE COVER PLATE 
  13. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  14. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  15. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing the fuel (engine room side) pump assembly.

      Refer to INITIALIZATION [10/2022 - ]

  16. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    Refer to WORK PROCEDURE [10/2022 - ]

    HINT: 

    When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [08/2023 - ]

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