Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	FUEL PUMP LIFTER ASSEMBLY	23470		-	-
2	FUEL PUMP SPACER GASKET	23224D	-	-	-
3	FUEL PUMP FLANGE	23191	-	-	-
4	TEMPORARILY INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY	23100X		-	-
5	TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY	23801P		-	-
6	INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY	23100X		-	-
7	INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY	23801P		-	-
8	FUEL TUBE SUB-ASSEMBLY	23910A		-	-
9	INTAKE MANIFOLD	17111	-	-	-
10	EGR VALVE ASSEMBLY	25620	-	-	-
11	CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
12	INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL	-	-	-
13	INSPECT FOR FUEL LEAK	-		-	-
14	INSPECT FOR ENGINE OIL LEAK	-		-	-
15	PERFORM INITIALIZATION	-	-	-

	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)	*	For use with a union nut wrench
●	Non-reusable part	-	-

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. INSTALL FUEL PUMP LIFTER ASSEMBLY

NOTICE: When replacing the fuel pump assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one Perform "Inspection After Repair" after replacing the fuel pump assembly. Click here

(1) 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.

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

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

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

(5) 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.

2. INSTALL FUEL PUMP SPACER GASKET

3. SET FUEL PUMP FLANGE

4. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

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

NOTICE:

Do not damage the O-ring.

(2) Set the fuel pump assembly on the cylinder head cover sub-assembly.

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

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.

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

(2) Connect the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.

(3) Temporarily install the bolt.

6. 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.

7. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(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.

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)

(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.

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)

(3) Using an 8 mm socket wrench, tighten the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(4) Connect the ignition coil assembly connector.

8. CONNECT FUEL TUBE SUB-ASSEMBLY

(1) Connect the fuel tube sub-assembly to the fuel pump assembly.

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9. INSTALL INTAKE MANIFOLD

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10. INSTALL EGR VALVE ASSEMBLY

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11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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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.

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13. INSPECT FOR FUEL LEAK

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14. INSPECT FOR ENGINE OIL LEAK

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15. PERFORM INITIALIZATION

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

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