Lexus ES: Installation

INSTALLATION

PROCEDURE

1. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY

(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.

*1 Fuel Pump Assembly *2 Fuel Pump Lifter Assembly *3 Camshaft *a Correct *b Incorrect *c Oil Collection Area

(b) 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.

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

*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)

(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 housing and the outside of the fuel pump lifter assembly.

*a Fuel Pump Lifter Assembly (Engine Oil Application Area) *b Fuel Pump Lifter Housing (Engine Oil Application Area) *c Stopper Key *d Key Groove

(f) 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.

(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 lifter guide and fuel pump assembly on the cylinder head cover sub-assembly as shown in the illustration.

*1 Fuel Pump Assembly *2 Fuel Pump Lifter Guide

(i) 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

NOTICE:

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

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

(b) 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

HINT:

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

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(a) Tighten the 2 bolts.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(b) Connect the fuel pump assembly connector.

4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) 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)

*a 17 mm Union Nut Wrench *b Torque Wrench Fulcrum Length

(b) 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.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

5. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

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

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6. INSTALL FUEL PUMP PROTECTOR

(a) 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}

(b) Engage the clamp to connect the fuel tube sub-assembly to the fuel pump protector.

7. INSTALL INTAKE MANIFOLD

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8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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9. INSPECT FOR FUEL LEAK

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10. PERFORM INITIALIZATION

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

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