Oil Pump Installation

Install 2 new O-rings to the cylinder block.

Remove any old seal packing (FIPG material) from the timing gear case and cylinder block.

Set a new gasket to the timing gear case.

Apply seal packing to the areas shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

4 mm (0.15 in.)

NOTICE:

1. After applying seal packing, install the timing gear case within 3 minutes and tighten the bolts within 15 minutes.
   
2. Do not start the engine for at least 2 hours after the installation.
   

Align the "2" timing marks of the No. 1 balance shaft driven gear and oil pump drive gear, and install the timing gear case to the cylinder block.

Install the timing gear case with the 8 bolts and union bolt.

Torque:

for bolt:

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

for union bolt (A):

16 N*m{163 kgf*cm, 12 ft.*lbf}

Make sure that the oil pump drive gear rotates smoothly.

NOTICE:

If the gear does not rotate smoothly, remove the 8 bolts and union bolt to release the gear. Then install the bolts and gear again.

Install a new gasket and the oil strainer with the 2 bolts and nut.

Torque:

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

Remove any old seal packing (FIPG) from the oil pan and cylinder block.

Apply seal packing to the areas shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

4 mm (0.15 in.)

NOTICE:

1. After applying seal packing, install the oil pan within 3 minutes and tighten the bolts within 15 minutes.
   
2. Do not start the engine for at least 2 hours after the installation.
   

Install the oil pan with the 22 bolts and 2 nuts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

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}

Align the "3" timing marks of the injection gear and balance No. 2 shaft driven gear, and install the injection gear.

NOTICE:

Fit the key (protrusion) of the supply pump to the key slot of the injection gear.

Set a new O-ring and then temporarily install the nut. Using your hand, check the thrust clearance of the supply pump drive shaft by driving the injection gear.

Thrust clearance:

0.15 to 0.55 mm (0.0059 to 0.0217 in.)

HINT:

If the clearance is not within the specified range, remove the injection gear again and reinstall it.

Align the "1" timing marks of the oil pump drive gear and crankshaft timing gear as shown in the illustration.

Using SST, install the crankshaft timing gear.

SST

09223-00010

Install the No. 1 idle gear shaft to the cylinder block.

Align the "4" timing marks of the No. 1 idle gear and injection gear, as shown in the illustration.

Align the "5" timing marks of the No. 1 idle gear and crankshaft timing gear, and install the No. 1 idle gear, as shown in the illustration.

Install the idle gear thrust plate with the 2 bolts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Remove the service bolt.

Install the No. 1 crankshaft sensor plate.

Install a new O-ring to the timing gear case.

Remove any old seal packing (FIPG material) from the timing gear cover.

Apply seal packing to the areas shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

4 mm (0.15 in.)

NOTICE:

1. After applying seal packing, install the gear cover within 3 minutes and tighten the bolts and nuts within 15 minutes.
   
2. Do not start the engine for at least 2 hours after the installation.
   

Install the cover with the 14 bolts and 2 nuts.

Torque:

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

Install the No. 1 vacuum transmitting pipe with the bolt.

Torque:

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

Install the crankshaft position sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Install the camshaft position sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Align the pulley set key with the key groove of the pulley and install the pulley.

Using SST, install the pulley bolt.

SST

09213-58014
09330-00021

Torque:

365 N*m{3722 kgf*cm, 269 ft.*lbf}

Install a new O-ring to the supply pump.

Temporarily install the supply pump with the nut.

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

SST

09213-58014
09330-00021

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Install the No. 2 camshaft timing pulley flange and pump drive shaft pulley with the 4 bolts.

Torque:

31 N*m{316 kgf*cm, 23 ft.*lbf}

Using a dial indicator, check the thrust clearance of the pump drive shaft while moving the pump drive shaft pulley back and forth.

Thrust clearance:

0.15 to 0.55 mm (0.0059 to 0.0217 in.)

HINT:

If the clearance is not within the specified range, remove and reinstall the supply pump and pump drive shaft pulley. Then repeat the step above.

Install a new O-ring to the vane pump.

Install the vane pump with the 2 nuts.

Torque:

41 N*m{418 kgf*cm, 30 ft.*lbf}

Install 2 new O-rings to the vacuum pump.

Install the vacuum pump with the 2 nuts.

Torque:

21 N*m{210 kgf*cm, 15 ft.*lbf}

Install a new gasket and the water pump with the 5 bolts and 2 nuts.

Torque:

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

Apply seal packing (FIPG) to the specified areas shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:

After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

Install the No. 2 timing belt cover with the 4 bolts and nut.

Torque:

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

Install the timing belt idler and a new spacer with the bolt.

Torque:

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

Install the camshaft timing pulley.

Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

Torque:

98 N*m{1,000 kgf*cm, 72 ft.*lbf}

Remove any old seal packing (FIPG) material from the cylinder head.

Apply seal packing to the specific areas shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the head cover within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the seal packing.
   

Install a new cylinder head cover gasket and the cylinder head cover with the 10 bolts and 2 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install 4 new nozzle holder seals.

Connect the ventilation hose.

Connect the 4 connectors and install the 3 bolts.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

Temporarily install the No. 4 injection pipe with the union nuts.

Install the 2 bolts.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

NOTICE:

1. If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
   
2. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   
3. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.
   

Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

Torque:

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

HINT:

If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. When replacing the common rail, it is necessary to replace the 4 injection pipes and fuel inlet pipe with new ones.
   
2. Be careful that dust, dirt or any other foreign matter does not contact the joint area of the fuel inlet pipe.
   

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the common rail side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the supply pump side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Install a new O-ring to the engine oil level dipstick guide.

Install the engine oil level 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}

Install the engine oil level dipstick.

Install the manifold stay with the 2 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

HINT:

Make sure the stay's indented area (labeled A) must face the manifold.

Install the No. 1 compressor mounting bracket with the 4 bolts.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Install the V-ribbed belt tensioner with the 4 bolts.

Torque:

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

HINT:

Firmly press and hold the V-ribbed belt tensioner against the cylinder block to eliminate any gaps in the areas labeled A in the illustration. Then uniformly tighten the 4 bolts.

Install the generator bracket with the bolt.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Install the generator with the 2 bolts.

Torque:

62 N*m{632 kgf*cm, 46 ft.*lbf}for bolt A

25 N*m{255 kgf*cm, 18 ft.*lbf}for bolt B

Install the generator wire with the nut.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the terminal cap.

Connect the generator connector.

Install the spacer, No. 2 idle pulley and pulley plate with the bolt.

Torque:

45 N*m{459 kgf*cm, 33 ft.*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}

Wipe the oil pan and drain plug.

Install a new gasket and the drain plug.

Torque:

34 N*m{347 kgf*cm, 25 ft.*lbf}

Add new oil.

Standard oil capacity:

Item	Specified Condition
Drain and refill with oil filter change	6.9 liters (7.3 US qts, 6.1 Imp. qts)
Drain and refill without oil filter change	6.6 liters (7.0 US qts, 5.8 Imp. qts)
Dry fill	7.4 liters (7.8 US qts, 6.5 Imp. qts)

Install the oil filler cap.

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 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.
   

Start the engine.

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 (Toyota Fortuner RM0000012WY005X.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 (Toyota Fortuner RM0000012WY005X.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 the fluid level.

Jack up the front of the vehicle and support it with stands.

Turn the steering wheel.

1. With the engine stopped, turn the steering wheel slowly from lock to lock several times.
   

Lower the vehicle.

Start the engine. Run the engine at idle for a few minutes.

Turn the steering wheel.

1. With the engine idling, turn the steering wheel to the left or right full lock position and hold it there for 2 to 3 seconds. Then turn the steering wheel to the opposite full lock position and hold it there for 2 to 3 seconds.
   

2. Repeat the step above several times.
   

Stop the engine.

Check for foaming or emulsification. If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

Check the fluid level.

Keep the vehicle level.

With the engine stopped, check the power steering fluid level in the oil reservoir. If necessary, add power steering fluid.

Power steering fluid:

ATF "DEXRON'' II or III

HINT:

If the fluid is hot, check that the fluid level is within the HOT range on the oil reservoir. If the fluid is cold, check that the fluid level is within the COLD range.

Start the engine and run it at idle.

Turn the steering wheel to the left or right full lock position, and then turn the steering wheel to the opposite full lock position. Repeat this several times to raise fluid temperature.

Standard fluid temperature:

75 to 80°C (167 to 176°F)

Check for foaming or emulsification. If foaming or emulsification is identified, bleed air from the power steering system.

With the engine idling, measure the fluid level in the oil reservoir.

Stop the engine.

Wait a few minutes and remeasure the fluid level in the oil reservoir.

Maximum fluid level increase:

5 mm (0.20 in.)

Check the fluid level.

Perform registration of the injector compensation codes (Toyota Fortuner RM0000012XK030X_02_0003.html).

Perform pilot quantity learning (Toyota Fortuner RM0000012XK030X_02_0009.html).

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.

Warm up the engine, stop the engine and wait for 5 minutes. The oil level should be between the dipstick's low and full level marks.
If the oil level is low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not add engine oil above the full level mark.