FUEL SUPPLY PUMP (w/o EGR Cooler) INSTALLATION


  1. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    A01E0JEE01

    1. Check that the injection gear in the timing gear case moves back and forth smoothly.

    2. Install a new O-ring to the pump.

    3. Apply a light coat of engine oil to the O-ring.

    4. A01E2NBE01

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

    5. A01E141E01

      Install the pump with the 2 nuts.

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

    6. Set a new O-ring before tightening the set nut.

    7. A01E0MBE01

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

      SST
      09213-58013
      09330-00021
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    8. A01DZC9E01

      Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.

      Thrust clearance
      0.15 to 0.55 mm (0.0059 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.

    9. A01DXJEE01

      Connect the 2 connectors.

    10. A01DYSWE01

      Connect the 2 fuel hoses.

    11. A01E008E06

      Temporarily install the fuel inlet pipe with the union nuts.

      Note


      • If the supply pump is replaced, the fuel inlet pipe must be replaced.

      • Keep the fuel inlet pipe free of foreign matter.

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

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with union nut wrench }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without union nut wrench }

      Tech Tips

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

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

      Torque:
      32 N*m  { 326 kgf*cm, 24 in.*lbf, for use with union nut wrench }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without union nut wrench }

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

    14. Install the oil level gauge guide with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    15. A01DW6AE01

      Install the clamp with the bolt.

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

  2. INSTALL TIMING BELT

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    1. Check that the timing marks are aligned as shown in the illustration.

      Tech Tips

      If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

      Note


      • The engine should be cold.

      • When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

    2. Using a 10 mm hexagon wrench, install the and timing belt idler pulley and new washer with the bolt.

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

    3. Check that the idler pulley moves smoothly.

      If it does not move smoothly, check the idler sub-assembly and washer.

    4. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

    5. A01E2YJE01

      Place the tensioner upright. Then set the press to the top of the tensioner.

      Note


      • Do not scratch or deform the rod end.

      • Press in the tensioner rod upward.

      • Protect the tip of the push rod with a cloth in order to prevent damage.

    6. Using a press, slowly push in the push rod using 981 to 9800 N (100 to 999 kgf, 220 to 2203 lbf) of force.

      Note

      Do not impose a load of over 9800 N (999 kgf, 2203 lbf) to the push rod.

    7. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    8. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

    9. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the 2 bolts and install the tensioner.

    10. A01DZUHE01

      Remove the 1.5 mm hexagon wrench from the tensioner.

    11. A01DWQTE02

      Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

  3. INSTALL NO. 1 TIMING BELT COVER


    1. Install the timing belt cover with the 6 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Install the wire harness clamp.

    3. Install the water hose clamp with the bolt.

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

  4. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator assembly Click here.

  5. ADD AUTOMATIC TRANSMISSION FLUID

    Tech Tips

    Drive the vehicle so that the engine and transmission are at normal operating temperature.

    ATF temperature
    70 to 80° C (158 to 176° F)

    1. A01E0FXE01

      Park the vehicle on a level surface and set the parking brake.

    2. With the engine idling and the brake pedal depressed, move the shift lever into all positions from P to L. Then return it to P.

    3. Pull out the dipstick and wipe it clean.

    4. Push it back fully into the pipe.

    5. Pull it out and check that the fluid level is in the HOT range.

      If there are leaks, it is necessary to repair or replace O-rings, FIPG, oil seals, plugs or other parts.

  6. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01DYVNE01

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

      Standard capacity
      Item Specified Condition
      A/T 11.1 liters (11.7 US qts, 9.8 Imp. qts)
      M/T 9.8 liters (10.4 US qts, 8.6 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.

      Note

      Never use water as a substitute for engine coolant.

    4. 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.

    5. Install the radiator reservoir cap.

    6. A01DY58E01

      Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. 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 2,500 to 3,000 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.

    8. A01E2D9E01

      After the coolant cools down, check that the coolant level is at the F line.

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

  7. ADD FUEL

  8. TIGHTEN FUEL TANK CAP ASSEMBLY

  9. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      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. 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 to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DVKYE03

      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.

      A01DYT1E05

      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.

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  11. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

  12. FUEL SUPPLY PUMP INITIALIZATION


    1. Initialize the fuel supply pump Click here.

  13. START ENGINE

  14. CHECK FOR ENGINE COOLANT LEAKS

    Note

    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. A01E06UE01

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

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 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 cylinder block and head.

  15. CHECK FOR OIL LEAKS

  16. CHECK FOR FUEL LEAKS

    CAUTION:


    • During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

    • During Active Test mode, fuel becomes high-pressured. 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 push the intelligent tester main switch 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.

  17. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the under cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  18. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the under cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }