FUEL SUPPLY PUMP (w/o 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.

INSTALL FUEL SUPPLY PUMP ASSEMBLY
1. Check that the supply pump gear in the timing gear case moves back and forth smoothly.
2. Install a new O-ring to the fuel supply pump.
3. Apply a light coat of engine oil to the O-ring.
4. Align the groove of the supply pump gear with the set key on the drive shaft.
5. Install the fuel supply pump with the 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Install a new O-ring.
7. Using SST, hold the crankshaft pulley and install the set nut.
  
  SST
  
  09213-58014
  
  09330-00021
  
  Torque:
  
  64 N*m { 650 kgf*cm, 47 ft.*lbf }
8. 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 }
9. Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.
  
  Standard thrust clearance
  
  0.15 to 0.55 mm (0.00590 to 0.0217 in.)
  
  If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.
10. Connect the fuel temperature sensor connector and suction control valve connector.
11. Connect the 2 fuel hoses.
INSTALL NO. 1 FUEL SUPPLY PUMP PROTECTOR
1. Install the No. 1 fuel supply pump protector with the 2 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
INSTALL FUEL SUPPLY PUMP INSULATOR
1. Install the fuel supply pump insulator.
  
  Text in Illustration
  
  Front Side of Vehicle
  Note
  
  When installing the fuel pump supply insulator, be sure to hold down the part labeled A in the illustration.
  
  Make sure that the shape of the fuel supply pump insulator fits correctly with the timing gear case, cylinder block and oil cooler cover.

Standard thrust clearance
0.15 to 0.55 mm (0.00590 to 0.0217 in.)

Text in Illustration
	Front Side of Vehicle

INSTALL FUEL INLET PIPE SUB-ASSEMBLY

Temporarily install the fuel inlet pipe with the union nuts.
Note
- When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.
- Keep the fuel inlet pipe free of foreign matter.

Text in Illustration
*a	Common Rail Side
*b	Fuel Supply Pump Side

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the common rail side.

Torque:: 35 N*m { 357 kgf*cm, 26 ft.*lbf }

Note

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump side.

Torque:

35 N*m { 357 kgf*cm, 26 ft.*lbf }

Note

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

Text in Illustration
*1	No. 2 Nozzle Leakage Pipe
*2	Fuel Inlet Pipe
*3	Spool

Install the clamp with the bolt.

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

Note

Install the clamp between the spools.
Do not overlap the clamp and spool.

INSTALL NO. 1 INTAKE PIPE
1. Connect the No. 1 intake pipe with the air hose and install the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 2 clamps of the No. 1 air hose.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. Tighten the clamp of the intercooler air hose.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
4. Connect the vacuum hose to the manifold absolute pressure sensor connector.
5. Connect the 3 connectors to the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.
6. Attach the 2 clamps.
CONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
1. Connect the No. 4 vacuum transmitting pipe with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT HEATER WATER PIPE SUB-ASSEMBLY
1. Connect the inlet heater water hose with the bolt.
  
  Torque:
  
  26 N*m { 260 kgf*cm, 19 ft.*lbf }
CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY
1. Temporarily install the vane pump oil reservoir with the 3 bolts.
2. Tighten the 3 bolts of the vane pump oil reservoir in the order shown in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL INJECTOR DRIVER
1. Install the injector driver assembly with the 3 bolts.
  
  Torque:
  
  for bolt A
  
  13 N*m { 127 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the 3 connectors.
INSTALL TIMING BELT
1. Install the timing belt Click here.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.
Tighten the cylinder block drain cock plug.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
for Automatic Transmission	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
for Manual Transmission	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

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).
Please contact your TOYOTA dealer for further details.
for Cold Area Specification Vehicles:

Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

Note

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level drops below the B line, add TOYOTA SLLC to the B line.
Install the radiator reservoir cap.
Using a wrench, install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
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. Maintain the engine speed at 2500 to 3000 rpm.
3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
  CAUTION:
  
  When pressing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
4. Stop the engine and wait until the coolant cools down to ambient temperature.
  
  CAUTION:
  
  Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
After the coolant cools down, check that the coolant level is at the FULL line.

If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

BLEED AIR FROM FUEL SYSTEM
1. 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
  
  The maximum hand pump pumping speed is 2 strokes per second.
  
  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. Start the engine.
  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 on (IG) and turn the intelligent tester on.
6. Clear the DTCs Click here.
7. Start the engine.*1
8. 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 5th time.
  
  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.
INSPECT FOR COOLANT LEAK

Note

Before each inspection, turn the A/C switch off.

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 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 head.
INSPECT FOR FUEL LEAK
CAUTION:
- During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.
- During Active Test mode, fuel becomes highly pressurized. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.
1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.
2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.
3. Disconnect the return hose from the common rail.
4. Start the engine and check for fuel leaks from the return pipe.
  
  If there is fuel leakage, replace the common rail.
5. Connect the intelligent tester to the DLC3.
6. Start the engine and turn the intelligent tester on.
7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.
8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.
9. Check that there are no leaks from any part of the fuel system.
  
  Note
  
  A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.
  
  If there is fuel leakage, repair or replace parts as necessary.
10. Reconnect the return hose to the common rail.