| Last Modified: 05-13-2024 | 6.11:8.1.0 | Doc ID: RM1000000025V9T |
| Model Year Start: 2023 | Model: GR Corolla | Prod Date Range: [09/2022 - ] |
| Title: G16E-GTS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION; 2023 - 2025 MY GR Corolla [09/2022 - ] | ||
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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![2019 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2018 - ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION](/t3Portal/stylegraphics/info.gif)
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 camshaft faces the fuel pump lifter assembly. HINT: This prevents the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly. |
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(b) Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam. |
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(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.
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(e) Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly. |
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(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.
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(g) Apply engine oil to a new O-ring and install it to the fuel pump assembly. NOTICE: Do not damage the O-ring. |
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(h) Set the fuel pump flange and fuel pump assembly on the cylinder head cover sub-assembly.
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(i) Using an 8 mm socket wrench, temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement. |
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2. 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 sub-assembly 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.
3. INSTALL FUEL PUMP ASSEMBLY
(a) Using an 8 mm socket wrench, tighten the 2 bolts.
Torque:
28.5 N·m {291 kgf·cm, 21 ft·lbf}
(b) Connect the fuel pump assembly connector.
4. INSTALL INTAKE AIR RESONATOR
(a) Install the intake air resonator to the fuel pump flange with the bolt.
Torque:
21 N·m {214 kgf·cm, 15 ft·lbf}
5. INSTALL NO. 1 VACUUM TRANSMITTING HOSE
(a) Engage the 2 clamps to connect the No. 1 vacuum transmitting hose to the intake air resonator.
6. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe sub-assembly side of the No. 1 fuel pipe sub-assembly.
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*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:
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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.
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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)
(c) Tighten the bolt to the cylinder head cover sub-assembly.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
7. CONNECT ENGINE WIRE
(a) Engage the clamp to connect the engine wire.
(b) Install the bolt.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(c) Connect the camshaft position sensor connector.
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.
(b) Engage the clamp.
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 assembly.
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(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 PIPE CLAMP
(a) Install the fuel pipe clamp to the fuel tube connector.
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. CONNECT 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 NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL
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17. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
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18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
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19. INSTALL SPARE WHEEL CUSHION
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20. INSTALL DECK BOARD ASSEMBLY
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21. ADD ENGINE COOLANT
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22. INSPECT FOR FUEL LEAK
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23. INSPECT FOR ENGINE OIL LEAK
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24. PERFORM INITIALIZATION
(a) Perform "Inspection After Repair" after replacing the fuel pump assembly.
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25. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL
HINT:
When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.
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