FUEL PUMP (For High Pressure): Installation: Installation

1. Turn the camshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole as shown.
   Fig 1: Identifying Camshaft Correct And Incorrect Position

   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 cm³ (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.
   Fig 2: View Of Applying Coat Of Engine Oil To 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.
   Fig 3: Identifying Metal Eyelets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Install the insulator so that the open sides of the metal eyelets are facing outward as shown.
5. Temporarily install the fuel pump with the 2 nuts.
   Fig 4: Identifying Fuel Pump Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the fuel hose.
   Fig 5: Identifying Fuel Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown.
   Fig 6: Identifying O-Ring, Backup Rings (No. 1 And No. 2) And E-Ring

   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. Temporarily install the No. 3 fuel pipe to the delivery pipe with the 2 bolts.
   Fig 7: View Of Installing No. 3 Fuel Pipe To Delivery Pipe With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the No. 3 fuel pipe sub-assembly to the fuel pump.
   Fig 8: Identifying Fuel Pipe

   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.
4. Tighten the 2 bolts in several passes.

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

5. Tighten the 2 nuts in several passes.

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

6. Using a 19 mm union nut wrench, tighten the union nut.
   Fig 9: Tightening Union Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   without union nut wrench 

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

   with union nut wrench 

   Torque: 27 N*m (275 kgf*cm, 20 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.

   HINT: 

   • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.).
   • Make sure use union nut wrench and torque wrench are connected in a straight line.
7. Connect the fuel pump connector.

1. Attach the 5 claws and install the engine cover LH and RH to the fuel pump.
Fig 10: Identifying Cover Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT: 

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.

1. Install the fuel pressure pulsation damper. Refer to INSTALLATION .

1. Perform initialization. Refer to INITIALIZATION .
   NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable to the negative (-) battery terminal.