FUEL PUMP (for High Pressure): Installation

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.

   HINT:

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

   Fig 1: Identifying Camshaft And Oil Collector

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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 part.
   Fig 2: Identifying Pump Lifter

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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.
   NOTE: Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.
   Fig 3: Identifying Metal Eyelets

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5. Temporarily install the 2 nuts and fuel pump.
   Fig 4: Locating Fuel Pump Nuts

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6. Connect the fuel hose.
   Fig 5: Identifying Fuel Hose

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

   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.

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

   Fig 7: Locating Fuel Pipe Bolts

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3. Temporarily install the No. 3 fuel pipe sub-assembly to the fuel pump.
   Fig 8: Locating Fuel Pipe

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   NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
4. Install the No. 3 fuel pipe to the delivery pipe with the 2 bolts and tighten them in several passes.

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

5. Install the fuel pump with the 2 nuts and tighten them in several passes.

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

6. Using SST, tighten the union nut.

   SST 09023-12901 

   Torque: 

   without SST 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   with SST 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 (11.81 in).
   • Make sure SST and wrench are connected in a straight line.
   Fig 9: Tightening Union Nut

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7. Connect the connector to the fuel pump.

1. Attach the 5 claws and install the engine cover LH and RH to the fuel pump.
   Fig 10: Identifying Cover Sub-Assembly

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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 assembly (see INSTALLATION  ).

1. Install the intake manifold assembly (see INSTALLATION ).

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