Fuel Supply Pump -- Installation |
- NOTICE:
- When replacing the injectors (including shuffling the injectors between the cylinders), common rail, cylinder head or intake manifold, it is necessary to replace the injection pipes with new ones.
- w/ DPF:
When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines (Click here).
| 1. INSTALL FUEL SUPPLY PUMP |
- NOTICE:
- Do not push the supply pump drive gear.
Install a new O-ring to the supply pump.
Text in Illustration *1 New O-Ring
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Apply a light coat of engine oil to the O-ring.
Using an 8 mm x 1.25 pitch tap, remove the adhesive from the timing gear case bolt hole.
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Apply adhesive to 2 or more threads as shown in the illustration.
- Adhesive:
- Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Text in Illustration *1 Adhesive
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Align the set key on the drive shaft with the groove of the supply pump drive gear.
Text in Illustration *a Groove *b Set Key - NOTICE:
- Do not hold the supply pump by the parts indicated by the arrows in the illustration, as this may result in deformation, damage and fuel leakage.
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Temporarily install the fuel supply pump with the 2 nuts.
Using a 6 mm hexagon wrench, install the bolt.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
Tighten the 2 nuts.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
Using a wrench, hold the crankshaft.
Install the set nut.
- Torque:
- 68 N*m{693 kgf*cm, 50 ft.*lbf}
Turn the crankshaft 2 times, and check that there are no problems.
Using a dial indicator, check the thrust clearance of the supply pump drive shaft while moving the pump drive shaft gear back and forth.
- Standard thrust clearance:
- 0.05 to 0.30 mm (0.00197 to 0.0118 in.)
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Connect the fuel temperature sensor connector.
| 2. INSTALL NO. 1 FUEL PIPE |
Install 2 new gaskets and the No. 1 fuel pipe with the union bolt.
- Torque:
- 17 N*m{175 kgf*cm, 13 ft.*lbf}
| 3. INSTALL TIMING CHAIN COVER PLATE |
Install a new gasket and the cover plate with the 4 bolts.
- Torque:
- 9.1 N*m{93 kgf*cm, 81 in.*lbf}
| 4. INSTALL TIMING GEAR COVER INSULATOR (w/ Intercooler) |
w/o Viscous Heater:
Install the timing gear cover insulator with the 2 bolts.- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
w/ Viscous Heater:
Install the timing gear cover insulator.
| 5. INSTALL FUEL TUBE SUB-ASSEMBLY (w/ DPF) |
Attach the 3 clamps to install the fuel tube.
Connect the 3 fuel tube connectors (Click here).
| 6. INSTALL NO. 1 WATER BY-PASS PIPE |
| 7. INSTALL FUEL COOLER ASSEMBLY (w/o DPF) |
| 8. INSTALL THERMOSTAT |
| 9. INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System) |
| 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).
Connect the cables to the negative (-) main battery and sub-battery terminals.
| 11. PERFORM FUEL SUPPLY PUMP INITIALIZATION |