FUEL SUPPLY PUMP INSTALLATION


  1. INSTALL INJECTION PUMP DRIVE GEAR


    1. Clamp the injection pump assembly in a vise.

    2. A01CHKV

      Install the crankshaft angle sensor plate and the drive gear with the nut.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

    3. Install a new O-ring onto the timer cover.

    4. A01CGUZ

      Install the timer cover onto the supply pump with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  2. INSTALL SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring onto the timer cover.

    2. A01CH8BE01

      Turn the drive gear and align the hole with the matchmark as shown in the illustration.

    3. A01CJ11E01

      Check the No. 1 cylinder to TDC/compression.

    4. A01CH2IE01

      Align the matchmarks of the timer cover and the front end plate, and then install the supply pump assembly with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
    5. A01CHOV

      When the crankshaft position sensor's installation hole can be accessed directly:


      1. Check that the knock pin of the injection pump drive gear is at the center of the hole. If not, perform steps (b), (c), and (d) again. Then, proceed to step (g).

    6. A01CH68E01

      When the crankshaft position sensor's installation hole cannot be accessed directly:


      1. Tape the screwdriver as shown in the illustration.

      2. A01CIOUE02

        Remove the service plug and gasket from the timing chain cover sub-assembly.

      3. A01CJEHE01

        Insert the screwdriver into the service plug hole.

      4. Check that the tape end and timing chain cover sub-assembly are aligned as shown in the illustration. If not, perform steps (b) and (c) again.

      5. Install the service plug and gasket to the timing chain cover sub-assembly.

    7. A01CIH3

      Install the holder clip with the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    8. Connect the 2 connectors.

  3. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Install the crankshaft position sensor with a new O-ring and the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  4. INSTALL FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CHNN

      Temporarily install the fuel return pipe sub-assembly with the 2 union bolts and 5 new gaskets.

    2. Tighten the 2 union bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 15 ft.*lbf }

  5. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. A01CJB8

      Using a union nut wrench (17 mm), install the fuel filter to injection pump fuel pipe with the 2 union nuts.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

      Note


      • If the supply pump assembly has been replaced, the fuel filter to injection pump fuel pipe must also be replaced.

      • Refer to the torque above when not using SST. When using SST, calculate the torque in accordance with the lengths of SST and the torque wrench Click here.

    2. Install the fuel pipe clamp with the nut. Tighten the nut until the clamp edge makes contact with the engine side clamp edge.

    3. A01CHXB

      Connect the 2 wire harness clamps.

    4. Connect the wire harness connector.

  6. INSTALL FUEL PIPE SUB-ASSEMBLY


    1. Install the fuel pipe sub-assembly with the union bolt and 2 new gaskets.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    2. Install the 3 fuel pipe clamps with the 2 bolts and nut. Tighten the 2 bolts and nut until the clamp edges make contact with the engine side clamp edges.

  7. CONNECT FUEL HOSE


    1. A01CIXU

      Connect the 2 fuel hoses.

  8. INSTALL VENTURI ASSEMBLY


    1. A01CI8SE01

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the intake pipe with the EGR valve within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the venturi assembly with the 4 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  9. INSTALL DIESEL THROTTLE BODY


    1. Remove any seal packing material from the contact surface.

    2. A01CJAVE01

      Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.

      Tech Tips


      • Remove any oil from the contact surface.

      • Install the diesel throttle body assembly within 3 minutes of applying the seal packing.

      • Do not run the engine for at least 2 hours after installing.

    3. A01CH93

      Install the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CHFJ

      Connect the 2 diesel throttle body connectors.

  10. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJ9R

      Install 4 new gaskets and water by-pass pipe sub-assembly with the 2 union bolts and 3 bolts.

      Torque:
      for Union Bolt
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for Bolt
      29 N*m  { 29 kgf*cm, 21 ft.*lbf }
    2. A01CJ16

      Connect the 2 hoses to the EGR valve.

  11. INSTALL EGR VALVE BRACKET


    1. A01CISY

      Install the EGR valve bracket with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  12. INSTALL WIRE HARNESS AND CONNECTORS


    1. A01CJDO

      Connect the 3 connectors and 3 connector clamps and then install the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  13. INSTALL EGR COOLER SUB-ASSEMBLY


    1. Install the EGR cooler with a new gasket and the 2 bolts.

      Torque:
      Flange
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }
      Engine
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

    2. Connect the water by-pass hose.

  14. INSTALL NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE


    1. A01CJ3X

      Connect the No. 1 intake air pipe with No. 4 air hose with a new hose band.

    2. A01CHDR

      Connect the intake air temperature sensor connector.

    3. A01CIPV

      Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. A01CGN2

      Install the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    5. A01CJ0J

      Install the No. 1 intake air pipe with No. 4 air hose with a new hose band.

  15. INSTALL NO. 1 AIR HOSE


    1. A01CJCPE01

      Install the No. 1 air hose with the 2 bolts and a new hose clamp as shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  16. INSTALL NO. 2 INTAKE PIPE


    1. A01CHOY

      Install the No. 2 intake pipe with the 3 bolts and 2 bands.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  17. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH

  18. ADD ENGINE COOLANT


    1. Add engine coolant.

      Specified capacity
      14.7 liters (15.5 US qts, 12.9 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

      • Contact your TOYOTA dealer for further details.

    2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.

    3. Install the radiator cap.

    4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

    5. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens.

        While the thermostat is open, circulate the coolant for several minutes.

      2. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        Note


        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. Stop the engine and wait until the coolant cools down.

    7. Remove the radiator cap and check the coolant level.

    8. If the coolant level has dropped, add coolant.

    9. Check the coolant level inside the radiator reservoir tank again. If it is below the full level, add coolant.

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  20. BLEED AIR FROM FUEL SYSTEM

    Tech Tips

    Click here.

  21. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine.

      3. Turn the intelligent tester on.

      4. Select the following menu items: Powertrain / Engine / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Fuel leaks (common rail internal fuel pressure is raised) Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when Start is selected.

        • Above conditions preserved while Start is selected.

  22. INSPECT FOR COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

      Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. A01CIGLE01

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    5. Install the radiator cap.

  23. INSPECT FOR OIL LEAK

  24. INSTALL ENGINE UNDER COVER

  25. SUPPLY PUMP INITIALIZATION

    Tech Tips

    Click here.

  26. PERFORM INITIALIZATION

    Tech Tips

    Click here.