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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 19 (Fuel System (A25A-FXS) - Service Information (2 Of 2)) >> FUEL PUMP (for High Pressure) >> Installation [11/2023 - ] >> Procedure

Installation [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    NOTE:

    When replacing the fuel pump assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

    HINT: 

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

    Refer to INITIALIZATION [10/2021 - ]

    1. Turn the crankshaft pulley until the flat of the No. 2 camshaft faces the fuel pump lifter assembly.
      GTY750671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Assembly
      *2 Fuel Pump Lifter Assembly
      *3 No. 2 Camshaft
      *a Correct
      *b Incorrect

      HINT: 

      This prevents the No. 2 camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly.

    2. Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam.
      GTY888950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Spacer Gasket
      *a Pump Drive Cam (Engine Oil Application Area)
      *b Fuel Pump Lifter Assembly (Engine Oil Application Area)
    3. Apply engine oil to the fuel pump lifter assembly.
    4. Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly and No. 4 camshaft bearing cap.
    5. Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.
      GTY855559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Pump Lifter Assembly (Engine Oil Application Area)
      *b Fuel Pump Lifter Guide (Engine Oil Application Area)
      *c Stopper Key
      *d Key Groove
    6. 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.

    7. Apply engine oil to a new O-ring and install it to the fuel pump assembly.
      NOTE:

      Do not damage the O-ring.

    8. Set the fuel pump flange and fuel pump assembly on the No. 4 camshaft bearing cap as shown in the illustration.
      GTY772911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Assembly
      *2 Fuel Pump Flange
    9. Temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement.
  2. 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. Temporarily install the bolt.
    2. Temporarily install the No. 1 fuel pipe sub-assembly to the fuel delivery pipe and tighten the union nut by hand.
    3. Temporarily install the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.
  3. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    1. Tighten the 2 bolts.

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

    2. Connect the fuel pump assembly connector.
  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. for EGR Valve Bracket Connection Type:
      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.
        GTY910660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 17 mm Union Nut Wrench
        *b Torque Wrench Fulcrum Length
        Union Nut
        Bolt

        Specified tightening torque 

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

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

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

          Refer to PRECAUTION [11/2023 - ]

        • 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 pump assembly side of the No. 1 fuel pipe sub-assembly.

        Specified tightening torque 

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

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

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

          Refer to PRECAUTION [11/2023 - ]

        • 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) 

    2. for Cylinder Head Cover Sub-assembly Connection Type:
      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.
        GTY1002135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 17 mm Union Nut Wrench
        *b Torque Wrench Fulcrum Length
        Union Nut
        Bolt

        Specified tightening torque 

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

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

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

          Refer to PRECAUTION [11/2023 - ]

        • 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 pump assembly side of the No. 1 fuel pipe sub-assembly.

        Specified tightening torque 

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

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

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

          Refer to PRECAUTION [11/2023 - ]

        • 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) 

    3. Connect the ignition coil connector.
  5. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B).
      GTY752505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).
    3. Tighten the bolt (B).

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

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

      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.

      GTY751234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45°
      *b Left Side of Vehicle
    6. Engage the clamp to connect the HV air conditioning wire.
  6. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly to the fuel pump assembly and fuel delivery pipe sub-assembly.

      Refer to PRECAUTION [11/2023 - ]

    2. Install the fuel pipe clamp to the fuel tube connector.
  7. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [09/2020 - ]

  8. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  9. INSTALL BATTERY SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 66

  10. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

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

      Refer to INITIALIZATION [10/2021 - ]

  12. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    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 [11/2023 - ]

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