FUEL SUPPLY PUMP > INSTALLATION

for Preparation Click here



1. INSTALL FUEL SUPPLY PUMP ASSEMBLY


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

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

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



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



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  1. Install the pump with the 2 nuts.

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

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



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  1. 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 }



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  1. 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 step above.



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  1. Connect the 2 connectors.



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  1. Connect the 2 fuel hoses.



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  1. Temporarily install the fuel inlet pipe with the union nuts.

    NOTICE:
    1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
    2. Keep the fuel inlet pipe free of foreign matter.

  1. Using SST, tighten the injection pipe union nut on the common rail side.

    SST
    09023-12701  

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

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

  1. Using SST, tighten the injection pipe union nut on the supply pump side.

    SST
    09023-12701  

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

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

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

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



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  1. 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.

    HINT:
    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.

    NOTICE:
    1. The engine should be cold.
    2. When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

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

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

  1. Check that the idler pulley moves smoothly.
    If it does not move smoothly, check the idler sub-assembly and washer.

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



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

    NOTICE:
    1. Do not scratch or deform the rod end.
    2. Press in the tensioner rod upward.
    3. Protect the tip of the push rod with a cloth in order to prevent damage.

  1. Using a press, slowly push in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force.

    NOTICE:
    Do not impose a load of over 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) to the push rod.

  1. 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.

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

  1. Tighten the 2 bolts.

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

    NOTICE:
    Uniformly tighten the 2 bolts and install the tensioner.



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  1. Remove the 1.5 mm hexagon wrench from the tensioner.



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  1. 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 }

  1. Install the wire harness clamp.

  1. 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

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

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



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

  1. 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.

  1. Pull out the dipstick and wipe it clean.

  1. Push it back fully into the pipe.

  1. 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.

  1. Tighten the cylinder block drain cock plug.

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



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

    Standard capacity:
    9.0 liters (9.5 US qts, 7.9 lmp. qts)

    HINT:
    1. 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).
    1. Please contact your TOYOTA dealer for further details.

    NOTICE:
    Never use water as a substitute for engine coolant.

  1. 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.

  1. Install the radiator reservoir cap.



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  1. Using a wrench, install the vent plug.

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

  1. 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 2,000 to 2,500 rpm.

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

      CAUTION:
      When pressing the radiator hoses:
      1. Wear protective gloves.
      1. Be careful as the radiator hoses are hot.
      1. 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.



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  1. 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


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  1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.



10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


11. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    NOTICE:
    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
If the engine does start, see page .


14. CHECK FOR ENGINE COOLANT LEAKS


15. CHECK FOR OIL LEAKS


16. CHECK FOR FUEL LEAKS


17. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 2 bolts.

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



18. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 4 bolts.

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