Toyota Yaris: Fuel Pump (for High Pressure) / Installation

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / Fuel Pump (for High Pressure) / Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY

NOTICE:

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.

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(a) Turn the crankshaft pulley until the flat of the No. 2 camshaft faces the fuel pump lifter assembly.

HINT:

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

*1

Fuel Pump Assembly

*2

Fuel Pump Lifter Assembly

*3

No. 2 Camshaft

*a

Correct

*b

Incorrect

(b) Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam.

*1

Fuel Pump Spacer Gasket

*a

Pump Drive Cam (Engine Oil Application Area)

*b

Fuel Pump Lifter Assembly (Engine Oil Application Area)

(c) Apply engine oil to the fuel pump lifter assembly.

(d) Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.

(e) Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.

*a

Fuel Pump Lifter Assembly (Engine Oil Application Area)

*b

Fuel Pump Lifter Guide (Engine Oil Application Area)

*c

Stopper Key

*d

Key Groove

(f) 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.

(g) Apply engine oil to a new O-ring and install it to the fuel pump assembly.

NOTICE:

Do not damage the O-ring.

(h) Set the fuel pump flange and fuel pump assembly on the cylinder head cover sub-assembly as shown in the illustration.

(i) Temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement.

2. INSTALL INTAKE AIR RESONATOR

(a) Install the intake air resonator to the fuel pump flange with the bolt.

3. INSTALL NO. 1 VACUUM TRANSMITTING HOSE

(a) Engage the 2 clamps and connect the No. 1 vacuum transmitting hose.

4. CONNECT ENGINE WIRE

(a) Engage the clamp and connect the engine wire.

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Connect the 2 connectors.

5. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

NOTICE:

Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly.

(a) Temporarily install the bolt.

(b) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel delivery pipe and tighten the union nut by hand.

(c) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.

6. INSTALL FUEL PUMP ASSEMBLY

(a) Tighten the 2 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

(b) Connect the fuel pump assembly connector.

7. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) 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.

*a

17 mm Union Nut Wrench

*b

Torque Wrench Fulcrum Length

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

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

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  • 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)

(b) 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.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

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

    Click here

  • 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)

(c) Tighten the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

8. CONNECT NO. 1 WATER BY-PASS HOSE

(a) Connect the No. 1 water by-pass hose and slide the clip to secure it.

9. CONNECT NO. 8 WATER BY-PASS HOSE

(a) Connect the No. 8 water by-pass hose and slide the clip to secure it.

10. INSTALL NO. 2 FUEL TUBE SUB-ASSEMBLY

(a) Connect the No. 2 fuel tube sub-assembly to the fuel pump assembly and fuel delivery pipe.

(b) Install the No. 2 fuel tube sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

11. INSTALL FUEL HOSE CLAMP

(a) Install the fuel pipe clamp to the No. 2 fuel tube sub-assembly.

12. CONNECT NO. 1 FUEL TUBE SUB-ASSEMBLY

(a) Connect the No. 1 fuel tube sub-assembly to the No. 2 fuel tube sub-assembly.

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13. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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14. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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15. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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16. INSTALL WATER GUARD PLATE RH

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17. INSTALL FRONT NO. 1 VENTILATOR SEAL

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18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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19. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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20. 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.

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21. INSPECT FOR FUEL LEAK

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22. PERFORM INITIALIZATION

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

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