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. A01CH8BE03
      Text in Illustration
      *a Matchmark
      *b Hole

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

    3. A01CJ11E05
      Text in Illustration
      *a Timing Mark

      Check that the No. 1 cylinder is at TDC/compression.

    4. A01CH2IE02
      Text in Illustration
      *a Matchmark

      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. A01CH68E03
      Text in Illustration
      *1 Vinyl Tape

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


      1. Tape the screwdriver as shown in the illustration.

      2. A01CIOUE03
        Text in Illustration
        *1 Service Plug

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

      3. A01CJEHE02
        Text in Illustration
        *1 Timing Chain Cover
        *2 Screwdriver
        *3 Drive Gear

        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 a new gasket to the timing chain cover sub-assembly.

        Torque:
        13 N*m  { 132 kgf*cm, 10 ft.*lbf }
    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. Install the crankshaft position sensor and a new O-ring with the bolt.

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

  4. INSTALL FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CHNNE01

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

    2. Tighten the 2 union bolts.

      Torque:
      Bolt A
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }
      Torque:
      Bolt B
      10 N*m  { 100 kgf*cm, 7 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 the union nut wrench. When using the union nut wrench, calculate the torque in accordance with the lengths of the union nut wrench and 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 and 2 new gaskets with the union bolt.

      Torque:
      17 N*m  { 170 kgf*cm, 12 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. Connect the 2 fuel hoses.

  8. INSTALL VENTURI ASSEMBLY


    1. A01CI8SE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.

      • Install the venturi within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the venturi assembly with the 4 bolts and 2 nuts.

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

    3. Install the bracket with the bolt.

      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. A01CJAVE02
      Text in Illustration
      *1 70 mm (2.75 in.)
      *2 Seal Packing

      Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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. A01CJB2E01
      Text in Illustration
      *1 Bolt
      *2 Union Bolt

      Install 4 new gaskets and the 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  { 291 kgf*cm, 21 ft.*lbf }

    2. Connect the 3 wire harness clamps.

    3. Connect the 2 hoses to the EGR valve.

  11. INSTALL EGR VALVE BRACKET


    1. 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. Connect the 3 connectors and 4 wire harness 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, bracket and 2 new gaskets with the 6 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. Connect the No. 1 intake air pipe with No. 4 air hose with a new hose band.

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

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

    3. Install the bolt.

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

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

  15. INSTALL NO. 1 AIR HOSE


    1. A01CJCPE02
      Text in Illustration
      *a Upper Side

      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. Install the No. 2 intake pipe and No. 1 air hose with the 3 bolts and 2 new hose 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 is 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 sub-assembly.

    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 sub-assembly 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. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop or Start

        • Fuel pressure inside common rail is pressurized to specified value and engine speed is 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 sub-assembly.

      CAUTION:

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

    2. A01CIGLE02
      Text in Illustration
      *1 Radiator Cap Tester

      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 sub-assembly.

  23. INSPECT FOR OIL LEAK

  24. INSTALL ENGINE UNDER COVER

  25. SUPPLY PUMP INITIALIZATION

    Tech Tips

    Click here.