Fuel Supply Pump -- Removal |
- NOTICE:
- When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.
Replaced Parts (A) Pipes Requiring New Replacement - Injector assembly (including shuffling the injector assemblies between the cylinders)
- Common rail assembly
- Cylinder head sub-assembly
- No. 1 injection pipe sub-assembly
- No. 2 injection pipe sub-assembly
- Supply pump assembly
- Common rail assembly
- Cylinder block sub-assembly
- Cylinder head sub-assembly
- Cylinder head gasket
- Timing chain case assembly
- No. 1 injection pipe sub-assembly
- No. 2 injection pipe sub-assembly
- Fuel inlet pipe sub-assembly
- Injector assembly (including shuffling the injector assemblies between the cylinders)
- After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.
- The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.
- Make sure foreign matter does not enter the fuel path.
| 1. PRECAUTION |
- NOTICE:
- After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work. (LandCruiser RM000003YMD00TX.html)
| 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected. (LandCruiser RM000003YMF011X.html)
| 3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 1 engine under cover sub-assembly.
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| 4. REMOVE INTAKE MANIFOLD |
| 5. REMOVE INTERCOOLER AIR HOSE |
Loosen the 2 hose bands and remove the intercooler air hose.
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| 6. REMOVE NO. 2 INTERCOOLER AIR HOSE |
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Slide the 2 clips and disconnect the oil return hose.
Loosen the 2 hose clamps and remove the No. 2 intercooler air hose.
| 7. REMOVE NO. 1 RADIATOR HOSE |
Slide the 2 hose clamps and remove the No. 1 radiator hose.
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| 8. REMOVE RADIATOR RESERVOIR ASSEMBLY |
Detach the 2 clamps to disconnect the No. 2 water by-pass hose from the fan shroud.
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Slide the hose clamp and disconnect the No. 2 water by-pass hose from the water inlet.
Slide the hose clamp and disconnect the No. 1 water by-pass hose from the radiator assembly.
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Detach the 2 clamps to disconnect the No. 1 water by-pass hose from the fan shroud.
Remove the 3 bolts and radiator reservoir assembly.
| 9. DISCONNECT NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles) |
Disconnect 2 cables from 2 positive battery terminals.
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Detach the 3 wire harness clamps to disconnect the No. 3 engine wire from the fan shroud.
| 10. REMOVE FAN SHROUD |
Loosen the 4 nuts holding the fan with fluid coupling assembly.
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Remove the fan and generator V belt (LandCruiser RM00000122Y00LX_01_0004.html).
Remove the 2 bolts holding the fan shroud.
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Slide the fan shroud in upper side to detach the guide and remove the fan shroud together with the fan with fluid coupling assembly.
- NOTICE:
- Be careful not to damage the radiator core.
Remove the fan pulley.
| 11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY |
Remove the 3 bolts and V-ribbed belt tensioner assembly from the timing chain cover sub-assembly.
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| 12. REMOVE NO. 2 FUEL HOSE |
Slide the 2 clips and remove the No. 2 fuel hose from the supply pump assembly and No. 3 nozzle leakage pipe assembly.
| 13. REMOVE NO. 1 FUEL HOSE |
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Slide the 2 clips and remove the No. 1 fuel hose from the supply pump assembly and No. 2 fuel pipe.
| 14. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY |
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Remove the fuel injection pump cover subassembly from the supply pump assembly.
| 15. REMOVE FUEL PUMP MOTOR WIRE |
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Disconnect the fuel pump motor wire connector.
Detach the clamp and remove the fuel pump motor wire.
| 16. REMOVE TIMING CHAIN COVER PLATE |
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Remove the 3 bolts and timing chain cover plate.
Remove the gasket.
| 17. REMOVE SUPPLY PUMP ASSEMBLY |
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- NOTICE:
- Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.
- With SST set, do not turn the crankshaft more than a half rotation.
Align the timing mark of the crankshaft pulley subassembly and timing chain cover by rotating the crankshaft clockwise.
Text in Illustration *a Timing Mark
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Using SST, hold the crankshaft pulley assembly and loosen the fuel supply pump shaft nut.
Text in Illustration *a Hold 
Turn - SST
- 09213-58014(91551-80840)
09330-00021
- NOTICE:
- Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.
- HINT:
- Rotate the supply pump shaft nut once to loosen it.
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Loosen the 3 nuts from the supply pump assembly.
- NOTICE:
- Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.
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Install SST with 3 bolts.
- SST
- 09241-11010
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
- NOTICE:
- Install SST with the bolts included with SST.
- HINT:
- Make sure that the installation direction of SST is as shown in the illustration.
- Align the hexagonal portion of SST with the supply pump shaft nut to install SST.
Text in Illustration *a Engine Front Side *b Engine Rear Side *c SST Hexagonal Portion
Remove the 2 bolts and No. 1 fuel pump bracket from the supply pump assembly and cylinder block sub-assembly.
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Install the handle to SST. While holding the crankshaft pulley assembly in place with the crankshaft holding tool, turn the handle in the counterclockwise direction to disconnect the supply pump assembly.
- SST
- 09213-58014(91551-80840)
09330-00021
- SST
- 09241-11010
Text in Illustration *a Hold Turn
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Remove the 3 nuts and supply pump assembly from the timing chain case assembly.
Remove the O-ring from the supply pump assembly.
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