Fuel Supply Pump Installation

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

Install a new O-ring to the pump.

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

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

Install the pump with the 2 nuts.

Torque:

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

Set a new O-ring before installing the set nut.

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}

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 (0.0059 to 0.0217 in.)

Connect the 2 connectors.

Connect the 2 fuel hoses.

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.
   

Using 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

HINT:

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

Using union nut wrench, tighten the injection pipe union nut on the supply pump 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

Install the oil dipstick guide with the bolt.

Torque:

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

Install the clamp with the bolt.

Torque:

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

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.
   

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

Torque:

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

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

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

Place the tensioner upright. Then set a 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.
   

Using the 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.

Align the holes of the push rod and housing. Then pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.

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

Tighten the 2 bolts.

Torque:

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

NOTICE:

Uniformly tighten the 2 bolts and install the tensioner.

Remove the 1.5 mm hexagon wrench from the tensioner.

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

Install the timing belt cover with the 6 bolts.

Torque:

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

Install the wire harness clamp.

Install the water hose clamp with the bolt.

Torque:

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

Install the radiator (Toyota Fortuner RM00000144D007X_01_0001.html).

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 reservoir tank's B line.

Standard Capacity:

Item	Specified Condition
Manual transmission	9.8 liters (10.4 US qts, 8.6 Imp. qts)
Automatic transmission	11.1 liters (11.7 US qts, 9.8 Imp. 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 is a combination of low phosphates and organic acids).
   
2. Please contact your TOYOTA dealer for further details.
   

NOTICE:

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 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:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. 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 F line.
If the coolant level is below the F line, add TOYOTA SLLC to the F line.

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

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.

Install the under cover with the 2 bolts.

Torque:

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

Install the under cover with the 4 bolts.

Torque:

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