FUEL SUPPLY PUMP (w/ DPF) INSTALLATION

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. INSTALL FUEL SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring to the fuel supply pump assembly.

    2. Apply a small amount of clean engine oil to the O-ring.

    3. A01KIG7E02
      Text in Illustration
      *a Groove

      Align the groove of the injection gear with the set key on the drive shaft.

    4. Temporarily install the fuel supply pump with the 2 nuts.

    5. Install a new O-ring and the nut.

    6. A01KHLVE03

      Using SST, hold the crankshaft pulley and install the set nut.

      SST
      09213-58014
      09330-00021
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

    7. Tighten the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    8. Connect the fuel hose.

    9. Connect the fuel temperature sensor connector and suction control valve connector to the fuel supply pump.

  2. INSTALL PUMP DRIVE SHAFT PULLEY


    1. Install the pump drive shaft pulley and No. 2 camshaft timing pulley flange with the 4 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  3. INSTALL NO. 3 FUEL PIPE


    1. A01KGWWE03
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. Temporarily install 3 new gaskets and the No. 3 fuel pipe with the fuel check valve, 2 union bolts and 3 bolts.

      A01KHGRE02
      Text in Illustration
      *1 Gasket - -
      A01KGZT Union Bolt A01KF96 Fuel Check Valve
      A01KFFI Bolt - -

    3. Tighten the 2 bolts and fuel check valve.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    4. Using a socket hexagon wrench, tighten the 2 union bolts and bolt.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Union bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  5. INSTALL NO. 3 NOZZLE LEAKAGE PIPE


    1. A01KIBLE03
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. Temporarily install a new gasket and the No. 3 nozzle leakage pipe with the fuel check valve and bolt.

    3. Tighten the fuel check valve and bolt.

      Torque:
      Fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }
      Bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    4. Install the No. 2 injection pipe clamp with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    5. Connect the 3 fuel hoses.

  6. INSTALL VANE PUMP ASSEMBLY

    Click here

  7. INSTALL EGR COOLER ASSEMBLY

    Click here

  8. INSTALL TIMING BELT

    Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  10. ADD ENGINE COOLANT


    1. Pour coolant into the radiator until it overflows.

      Capacity
      Specification Capacity
      w/o Heater 9.8 liters (10.3 US qts, 8.6 Imp. qts)
      w/ Front Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Front and Rear Heater 11.5 liters (12.2 US qts, 10.1 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    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 securely.

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

    5. Warm up the engine until the thermostat opens.


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

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    6. Maintain the engine speed at 2000 to 2500 rpm.

    7. Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.

      CAUTION:


        When squeezing the radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

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

    9. Remove the radiator cap and check the coolant level inside the radiator.

    10. If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.

    11. Check the coolant level inside the radiator reservoir tank again.

      If it is below the full level, add coolant.

  11. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

    2. A01KH30E02
      Text in Illustration
      *1 Radiator Cap Tester

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

    3. Warm up the engine.

    4. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and head.

    5. Reinstall the radiator cap.

  12. BLEED AIR FROM FUEL SYSTEM


    1. A01KETN

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01KI71E05
      Text in Illustration
      *a

      Reference

      (Active Test Operation)

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01KH8CE14
      Text in Illustration
      *a Active Test Operation *b ON
      *c OFF *d time
      *e 1st time *f 2nd time
      *g 5th time *h 10 seconds
      *i 3 minutes - -

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs, as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  13. PERFORM REGISTRATION

    Click here

  14. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      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 Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurize the common rail interior and check for fuel leaks Stop/Start

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

        • Above conditions preserved while test is ON

          Tech Tips

          If this Active Test is performed when the engine is cold, combustion may become unstable. However, this is not a malfunction. It is only necessary to confirm that the pressure rises to the target pressure and that there are no fuel leaks.

  15. INSPECT FOR EXHAUST GAS LEAK