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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Fuel System (2GR-FKS) - Service Information >> FUEL PUMP (for High Pressure) >> Installation [12/2019 - 10/2022] >> Procedure

Installation [12/2019 - 10/2022]: Procedure

  1. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    1. Turn the crankshaft pulley until the flat of the camshaft faces the fuel pump lifter assembly.
      GTY627324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Assembly
      *2 Fuel Pump Lifter Assembly
      *3 Camshaft
      *a Correct
      *b Incorrect
      *c Oil Collection Area

      HINT: 

      This prevents the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly.

    2. Fill the fuel pump lifter housing oil collection areas with 30 cc (1.8 cu. in.) of engine oil from the fuel pump assembly hole of the cylinder head cover sub-assembly.
    3. Apply engine oil to the pump drive cam and fuel pump lifter assembly.
      GTY635606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Cover Sub-assembly
      *2 Fuel Pump Spacer Gasket
      *3 Fuel Pump Lifter Housing
      *a Pump Drive Cam (Engine Oil Application Area)
      *b Fuel Pump Lifter Assembly (Engine Oil Application Area)
    4. Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.
    5. Apply engine oil to the inside of the fuel pump lifter housing and the outside of the fuel pump lifter assembly.
      GTY644892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Pump Lifter Assembly (Engine Oil Application Area)
      *b Fuel Pump Lifter Housing (Engine Oil Application Area)
      *c Stopper Key
      *d Key Groove
    6. Set the fuel pump lifter assembly on the fuel pump lifter housing 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 housing.

    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 lifter guide and fuel pump assembly on the cylinder head cover sub-assembly as shown in the illustration.
      GTY715466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Assembly
      *2 Fuel Pump Lifter Guide
    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 No. 1 fuel pipe sub-assembly to the fuel delivery pipe RH and tighten the union nut by hand.
    2. 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 

    HINT: 

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

    Refer to INITIALIZATION [12/2019 - 10/2022]

    1. Tighten the 2 bolts.

      Torque: 26 N.m (265 kgf/cm, 19 ft.lbf) 

    2. Connect the fuel pump assembly connector.
  4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. 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.
      GTY861044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      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 [12/2019 - 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 delivery pipe RH 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 [12/2019 - 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)
  5. INSTALL FUEL HOSE BRACKET 
    1. Install the fuel hose bracket to the cylinder head cover sub-assembly with the bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  6. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY 
    1. Engage the clamp and connect the No. 2 fuel tube sub-assembly to the fuel pump assembly.

      Refer to PRECAUTION [12/2019 - 10/2022]

  7. INSTALL FUEL PUMP PROTECTOR 
    1. Install the fuel pump protector to the cylinder head sub-assembly with the 2 bolts.

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

    2. Engage the clamp to connect the fuel tube sub-assembly to the fuel pump protector.
  8. INSTALL EXHAUST MANIFOLD ASSEMBLY RH (TWC: Front Catalyst) (for AWD) 

    Refer to INSTALLATION [12/2019 - 10/2022]

  9. INSTALL INTAKE MANIFOLD 

    Refer to INSTALLATION [12/2019 - 10/2022]

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  11. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

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

      Refer to INITIALIZATION [12/2019 - 10/2022]

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