High Pressure Fuel Pump

This procedure replaces the high-pressure fuel pump on a 2018-2024 Toyota Camry with the 2.5L I4 engine, which supplies pressurized fuel to the direct injection system.

Warnings

Tools required

Parts

• High-pressure fuel pump assembly × 1 — Toyota OEM 23100-36020 or equivalent
• Fuel pump O-rings (various sizes) × 1 — Included in Toyota seal kit 23291-21020
• Fuel line O-rings × 4 — Use OEM specification
• Engine cover clips (if broken) — Use OEM specification

Preparation

1. Ensure engine is completely cold (at least 4 hours since last operation)
2. Park vehicle on level ground, apply parking brake, and chock rear wheels
3. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
4. Relieve fuel system pressure: Remove fuel pump relay (C/OPN or EFI fuse in engine bay fuse box), attempt to start engine until it stalls, then crank for 5 seconds to ensure complete depressurization
5. Reinstall fuel pump relay after pressure relief
6. Place absorbent pads and drain pan under work area to catch residual fuel
7. Remove engine cover by pulling upward on clips at each corner

Procedure

1. 1

   Remove air intake components
   Disconnect the intake air temperature sensor connector. Loosen the hose clamp at the throttle body and remove the air intake tube. Remove the air filter housing cover and filter. Unbolt and remove the air filter housing lower section to access the fuel pump area.
2. 2

   Disconnect fuel feed line from rail
   Locate the high-pressure fuel line connection at the fuel rail (passenger side of engine). Use a shop towel to catch any residual fuel. Use the appropriate fuel line disconnect tool to release the quick-connect fitting. Pull the line straight out to avoid damaging the O-ring seat. Cover the open connection with a clean shop towel.
   ⚠Expect 10-20ml of residual fuel to spray when disconnecting. Keep towels ready and avoid contact with skin.
3. 3

   Remove fuel delivery pipe cover
   Locate the fuel delivery pipe vacuum switching valve and disconnect the vacuum hose. Remove the three screws securing the fuel delivery pipe cover (located above the high-pressure pump near the engine block). Carefully lift the cover away.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Disconnect high-pressure fuel line from pump
   The high-pressure line connects to the top of the pump with a threaded fitting. Using a flare nut wrench or appropriate tool, carefully loosen the fitting by turning counterclockwise. Support the pump body while turning to avoid damage. Once loose, unthread completely by hand and move line aside. Expect residual fuel spillage.
   ⚠This connection contains residual high-pressure fuel. Work slowly and keep the area clear of ignition sources.
5. 5

   Disconnect low-pressure fuel inlet
   On the lower side of the pump, locate the low-pressure fuel inlet line. Use the appropriate quick-disconnect tool to release the connection. Pull straight out and cover with a clean towel.
6. 6

   Disconnect pump electrical connector
   Press the release tab on the pump electrical connector and pull straight out to disconnect. Move the wiring harness aside to provide clearance.
7. 7

   Remove pump mounting bolts
   Remove the two mounting bolts securing the high-pressure fuel pump to the cylinder head. These bolts are typically 12mm heads. Support the pump while removing the final bolt to prevent it from falling.
   ⚠The pump is driven by the camshaft through a cam lobe. Note the orientation for reinstallation.
   Torque spec

   Pump Mounting14 Nm (10 lb-ft)
8. 8

   Remove high-pressure fuel pump
   Carefully pull the pump straight out from the cylinder head. The pump drive shaft engages with the camshaft, so pull firmly but steadily. Once clear, inspect the mounting surface and O-ring groove on the pump and cylinder head for damage or debris.
9. 9

   Inspect and clean mounting area
   Clean the pump mounting surface on the cylinder head with a lint-free cloth. Inspect the cam follower inside the cylinder head bore (visible with pump removed) for wear or scoring. Check that the camshaft lobe is intact. Remove any debris or old O-ring material from sealing surfaces.
10. 10

    Prepare new pump for installation
    Remove all O-rings from the new pump (or install new O-rings if reusing pump - NOT RECOMMENDED). Install new O-rings in all grooves on the pump body. Lubricate each O-ring with a small amount of clean gasoline. Verify the pump drive shaft rotates freely by hand. Apply a light coat of clean engine oil to the cam follower interface on the pump.
    ⚠️NEVER reuse old O-rings on fuel system components. This can result in high-pressure fuel leaks and fire.
11. 11

    Install new high-pressure fuel pump
    Align the pump drive shaft with the cylinder head bore and camshaft lobe. Push the pump straight in while rotating it slightly to engage the cam follower. Seat the pump fully against the cylinder head mounting surface. Install the two mounting bolts finger-tight, then torque in a cross pattern to specification.
    Torque spec

    Pump Mounting14 Nm (10 lb-ft)
12. 12

    Reconnect electrical connector
    Reconnect the pump electrical connector until it clicks into place. Verify the connector is fully seated and the locking tab is engaged.
13. 13

    Reconnect low-pressure fuel inlet
    Install a new O-ring on the low-pressure inlet line (if not integrated into quick-connector). Push the quick-connect fitting straight onto the pump inlet until you feel and hear a click. Pull back gently to verify connection is secure.
14. 14

    Reconnect high-pressure fuel line to pump
    Install a new O-ring on the high-pressure line fitting. Thread the fitting onto the pump outlet by hand until finger-tight. Using a torque wrench with appropriate socket or flare nut wrench, torque to specification. Support the pump body while tightening.
    ⚠️CRITICAL: This connection must be torqued exactly to specification. Under-torquing causes leaks; over-torquing damages threads. Both can result in fire.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
15. 15

    Reinstall fuel delivery pipe cover
    Position the fuel delivery pipe cover and install the three screws. Torque screws to specification. Reconnect the vacuum hose to the vacuum switching valve.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
16. 16

    Reconnect high-pressure line to fuel rail
    Install a new O-ring on the fuel rail connection. Push the quick-connect fitting straight onto the fuel rail until it clicks. Pull back gently to verify secure connection. Ensure the safety clip (if equipped) is properly seated.
    ⚠️This connection will experience full system pressure (up to 2900 psi). Verify proper seating before pressurizing system.
17. 17

    Reinstall air intake components
    Reinstall the air filter housing lower section and secure mounting bolts. Install the air filter and housing cover. Reconnect the air intake tube to the throttle body and tighten the hose clamp to specification. Reconnect the intake air temperature sensor.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
18. 18

    Reinstall engine cover and reconnect battery
    Align the engine cover with mounting clips and press down firmly until all clips engage. Reconnect the negative battery terminal.

Reassembly

1. Double-check all fuel line connections are fully seated and secured
2. Verify all electrical connectors are locked in place
3. Ensure no tools or shop towels are left in engine compartment
4. Remove all absorbent pads and dispose of fuel-soaked materials properly according to local regulations

Verification

• With ignition OFF, visually inspect all fuel connections for proper seating
• Turn ignition to ON position (do not start) for 2 seconds, then OFF. Repeat 4-5 times to prime fuel system and build pressure
• Inspect all fuel connections for leaks. Use a flashlight and look carefully - high-pressure leaks may be difficult to see
• Start engine and let idle for 2 minutes while monitoring for fuel odor or visible leaks
• Check for proper engine operation: smooth idle, no misfires, no fuel pressure codes
• Perform a test drive and verify normal acceleration and power delivery
• After test drive, re-inspect all fuel connections with engine off for any seepage or wetness
• Clear any diagnostic codes if present and verify no fuel system codes return
• If ANY fuel leak is detected at any point, immediately shut off engine, relieve fuel pressure, and correct the issue before operating vehicle

Related trouble codes on this vehicle

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