Fuel Supply Pump Installation

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

Install the O-ring to the supply pump assembly.

To insert the supply pump assembly shaft in the supply pump shaft sprocket, it may be necessary to turn the supply pump assembly several degrees and the groove in the supply pump assembly shaft are aligned.

HINT:

When installing a new supply pump assembly, adjust the supply pump assembly injection pump drive shaft key assignment by turning the supply pump assembly shown in the illustration.

Using SST, tighten clockwise direction the supply pump assembly, and then temporarily install the 3 fuel supply pump fixing nuts.

SST

09213-58014(91551-80840)
09330-00021
09241-11010

Text in Illustration

*a	Hold
	Turn

Using SST, tighten and insert the supply pump assembly up to the position shown in the illustration and tighten the 3 fuel supply pump fixing nuts.

Torque:

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

HINT:

After tightening the part with SST, a gap of 2 to 3 mm in area A shown in the illustration is normal.

Install the No. 1 fuel pump bracket with the 2 bolts to the supply pump assembly and cylinder block sub-assembly.

Torque:

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

Remove SST and the 3 set bolts.

Using SST, hold the crankshaft pulley subassembly and tighten the set nut.

SST

09213-58014(91551-80840)
09330-00021

Torque:

137 N*m{1397 kgf*cm, 101 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

Install the timing chain cover plate and new gasket with the 3 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Attach the clamp and install the fuel pump motor wire.

Connect the fuel pump motor wire connector.

Install the fuel injection pump cover sub-assembly to the supply pump assembly.

Install the No. 1 fuel hose to the supply pump assembly and No. 2 fuel pipe, and slide the 2 clamps to secure it.

Install the No. 2 fuel hose to the supply pump assembly and No. 3 nozzle leakage pipe assembly, and slide the 2 clamps to secure it.

Install the V-ribbed belt tensioner assembly to the timing chain cover sub-assembly with 3 bolts.

Torque:

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

Attach the 3 wire harness clamps to connect the No. 3 engine wire to the fan shroud.

Connect the 2 cables to the positive battery terminals.

Install the fan pulley.

Place the fan shroud together with the fan with fluid coupling assembly between the engine and radiator assembly.

NOTICE:

Be careful not to damage the radiator core.

Attach the 2 guides and install the fan shroud with the 2 bolts.

Torque:

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

Temporarily install the fan with fluid coupling assembly to the engine water pump assembly with the 4 nuts.

NOTICE:

1. Make sure to match the paint mark colors on the fan with fluid coupling assembly with the stud bolts of the same color on the engine water pump assembly.
   
2. When installing the fan and generator V belt, make sure to securely tighten the nuts of the fan with fluid coupling assembly so that the fan pulley is properly aligned.
   

Install the fan and generator V belt (LandCruiser RM00000122V00OX_01_0002.html).

Tighten the 4 nuts holding the fan with fluid coupling assembly.

Torque:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Install the radiator reservoir assembly with the 3 bolts.

Torque:

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

Attach the 2 clamps to connect the No. 1 water by-pass hose to the fan shroud.

Connect the No. 1 water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.

Connect the No. 2 water by-pass hose to the water inlet and slide the hose clamp to secure the hose.

Attach the 2 clamps to connect the No. 2 water by-pass hose to the fan shroud.

Install the No. 1 radiator hose and slide the 2 hose clamps to secure the hose.

Install the No. 2 intercooler air hose and tighten the 2 hose clamps.

Torque:

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

Connect the oil return hose and slide the 2 clips to secure the hose.

Install the intercooler air hose and tighten the 2 hose bands to secure the hose.

Torque:

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

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

NOTICE:

1. The maximum hand pump pumping speed is 2 strokes per second.
   
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 air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the engine switch off.

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   
2. w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.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 5th 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 /Trouble Codes.

Read Current DTCs.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.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 / Trouble Codes.

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 assembly.

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

Perform the Active Test.

1. Connect the GTS to the DLC3.
   

2. Turn the engine switch on (IG).
   

3. Turn the GTS on.
   

4. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.
   

5. If the GTS 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.
   

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

   HINT:

   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
   

Reconnect the return hose to the common rail assembly.

Install the No. 1 engine under cover with the 4 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}