Fuel Filter Replacement

Disconnect the clogging switch connector.

Move the clip to disconnect the hose connected to the filter inlet.

Connect a hose to the drain cock. Place the other side of the same hose into a container.

Loosen the drain cock to drain fuel (approximately 50 cc (3.0 cu. in.)).

Tighten the drain cock.

Using a screwdriver as a lever, loosen the fastener nut until it can be loosened by hand.

Fully loosen the fastener nut by hand.

To remove the cap, pull up one side of the cap, and then lift it off.

Remove the fuel filter element from the case.

Remove the case O-ring.

Attach 2 new O-rings to a new fuel filter element and a new O-ring to the case.

Install the fuel filter element to the case.

Align the mark on the cap and the mark on the case.

Push the cap onto the case by hand.

Standard clearance (A):

1.5 mm (0.0590 in.) or less

HINT:

The clearance between the cap and case should be even around the entire circumference of the cap and case.

Turn the fastener nut until a "click" sound is heard.

HINT:

Just before the marks of the case and nut align, the fastener nut will become more difficult to turn. Use a screwdriver as a lever to turn the fastener nut.

Measure the distance between the marks on the cap and case, and the clearance between the cap and case.

Standard distance (A):

1.0 mm (0.0393 in.) or more

Standard clearance (B):

1.0 mm (0.0393 in.) or less

Connect the hose to the filter inlet and install the clip as shown in the illustration.

Turn the ignition switch to ON.

After turning the ignition switch to ON, connect the clogging switch connector no sooner than 3 seconds have passed but no later than 60 seconds have passed.

Check that the combination meter's fuel system warning light turns off.

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

NOTICE:

1. Hand pump pumping speed: Max. 2 strokes/ sec.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. 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.
   
5. 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.
   
6. 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.
   

Check if the engine starts.

NOTICE:

1. 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.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. 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.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

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

Clear the DTCs.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0SYX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0T9X.html)
   

Start the engine.*1

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

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

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

HINT:

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.

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

Read Current DTCs.

Clear the DTCs.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0SYX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0T9X.html)
   

HINT:

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.

Repeat steps *1 to *3.

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

Read Current DTCs.

OK:

No DTCs are output.

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.

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.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and push the intelligent tester main switch on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

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.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.