1KD_RM.

book 1 ページ ２０１３年９月２７日　金曜日　午後１２時４７分

3-1

FUEL SYSTEM

SST LIST .......................................................................... 3-2

COMMON RAIL .............................................................. 3-3 0
REMOVAL, INSPECTION AND INSTALLATION............ 3-3
1
INJECTOR ....................................................................... 3-6
2
REMOVAL, INSPECTION AND INSTALLATION............ 3-6
3
SUPPLY PUMP ............................................................. 3-11
REMOVAL, INSPECTION AND INSTALLATION.......... 3-11
4
5
6
7
8
9
10
11
12
13
14
1KD_RM.book 2 ページ ２０１３年９月２７日　金曜日　午後１２時４７分

3-2

SST LIST
10-digit parts number is the components parts of 12-digit parts number with same figure.

Illustration Part No. Part Name

09213-76011-71
Crankshaft pulley holding tool
(

09280-76002-71
Inspection union bolt
(09280-00010)

09330-76001-71
Companion flange holding tool
(09330-00021)

09922-76001-71
Adjustable spanner
(09922-10010)
1
09950-76021-71
Puller C set
(09950-50013)
*1

09951-05010 Hanger 150

*1

09952-05010 Slide arm

*1

09953-05020 Center bolt 150

*1

09954-05021 Claw No.2

Revised April 15, 2014

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3-3

COMMON RAIL
REMOVAL, INSPECTION AND INSTALLATION
 Non-reusable parts T = N•m

T = 4 to 6

T = 31 to 39 4

T = 27 to 49
T = 31 to 39
6

3
T = 31 to 39

T = 4 to 6

T = 31 to 39

Removal and Installation Procedures

The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Exhaust manifold steps 1 and 3 See page 2-17  
2 Fuel inlet pipe S/A [Point 5]
3 Injection pipe clamp No.2 [Point 4]
4 Injection pipe S/A No.1 to 4 [Point 3]
5 Fuel hose No.3 [Point 2]
6 Common rail ASSY [Point 1]
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3-4

Caution:
• When the common rail ASSY is replaced, the fuel inlet pipe S/A and injection pipe S/A No.1 to 4 need
to be replaced as well.
• When installing pipes, clean the connected areas and remove foreign matters.
[Point 1]
Fuel pressure
limiter Caution:
Pressure sensor
Do not remove the pressure sensor and fuel pressure
limiter.

[Point 2]
Installation:
Topside
Direct the claw of clip as shown in the illustration.
Outside

[Point 3]
(1) (2) (3) (4) Installation:
Temporarily tighten both ends of the injection pipe S/A No.1 to
4 in the order shown at left.

(3) (4) (1) (2)

[Point 4]
Installation:
Install the injection pipe clamp No.2.
Caution:
• Fully tighten the injection clamp No.2 before tightening
the nuts of the injection pipe S/A No.1 to 4 fully.
• Make sure that the injection pipe S/A No.1 to 4 are held
by the clamps properly and there is no looseness
between the pipe and injection pipe clamp No.2.
1. Fully tighten the common rail ASSY side.
2. Fully tighten the injector ASSY side.
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3-5

[Point 5]
Caution:
• Fully tighten the injection pipe clamp before tightening the
fuel inlet pipe S/A fully.
• Make sure that the fuel inlet pipe S/A is held by the injection
pipe clamp properly and there is no looseness between
them.
1KD_RM.book 6 ページ ２０１３年９月２７日　金曜日　午後１２時４７分

3-6

INJECTOR
REMOVAL, INSPECTION AND INSTALLATION
 Non-reusable parts T = N•m

T = 8 to 10
䃂
5

T = 8 to 10
4

䃂 T = 10 to 15
T = 13 to 19

T = 19 to 24 䃂

䃂
6
7

8
䃂
䃂

3
䃂

T = 11 to 15

T = 17 to 25
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3-7

Removal and Installation Procedures

The installation procedure is the reverse of the removal procedure.
No. Item Disassembly Inspection Reassembly
1 Exhaust manifold steps 1, 3, 4, 5, 6 and 7 See page 2-17  
2 Common rail See page 3-3  
3 Nozzle leakage pipe ASSY No.2
4 Cylinder head cover ASSY [Point 6]
5 Nozzle holder seal [Point 5]
6 Nozzle leakage pipe ASSY No.1 [Point 1]
[Point 4]
7 Nozzle holder clamp [Point 2]
8 Injector ASSY [Point 3]

Caution:
• When the injector ASSY is replaced, the injection pipe S/A No.1 to 4 need to be replaced as well.
• When installing pipes, clean the connected areas and remove foreign matters.
[Point 1]
Caution:
Cover the injector with a plastic bag or the like to prevent intrusion of foreign matter.
[Point 2]
Caution:
Removed bolts, washers and nozzle holder clamps should be sorted by cylinder groups.
[Point 3]
Installation:
Install the injector ASSY.
ID code
Caution:
Since every injector ASSY has a different injection
characteristic, ID code registration (manual input) in the
engine ECU using SST (TaSCAN) is required.(See page 1-23
for details.)

Injector ASSY

1. Install the injection nozzle seat to the cylinder head.

2. Coat the O-ring with engine oil.
3. Insert the injector ASSY until it reaches the seat surface of the
cylinder head.
Caution:
• The injector ASSY must be installed to the cylinder which it
was removed from.
• Installing the injector ASSY to a different cylinder by
O-ring mistake may cause rough idling or abnormal noise.
4. Temporarily attach the common rail ASSY.
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3-8

5. Temporarily attach the injection pipe S/A No.1 to 4.

Caution:
When the injector ASSY is replaced, the injection pipe S/A
No.1 to 4 need to be replaced as well.

[Point 4]
Union bolt Installation:
Install the nozzle leakage pipe ASSY No.1.
Gasket 1. Coat the hollow screw and union bolt with engine oil.
2. Put the gasket and tighten the hollow screw and union bolt
by hand until they stop turning and temporarily attach the
nozzle leakage pipe ASSY No.1.
Caution:
Check that no sign of deformation or damage is seen on
the hollow screw and union bolt.

Gasket

Hollow
screw

3. Install the nozzle holder clamp by making the fork hold the
injector ASSY with the bolt at a fulcrum point.

Nozzle holder
clamp

4. Tighten the bolt through a washer.

Caution:
• Observe the correct washer direction.
• Make sure that the fork of the nozzle holder clamp holds
the injector ASSY. After that, tighten the bolt by hand
until it stops turning and then tighten it to the specified
torque.
5. Remove the injection pipe S/A No.1 to 4.
6. Remove the common rail ASSY.
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3-9

7. Tighten the hollow screws in the order shown in the illustration.

Union bolt 8. Tighten the union bolt.
Caution:
(4) Do not reuse the nozzle leakage pipe ASSY No.1 if it has been
tightened over the specified torque.
(3)

(2)

(1)

9. Check the nozzle leakage pipe ASSY No.1 for leakage.

SST (1) Install SST through the gasket.
SST 09280-76002-71, 23762-76001-71
T = 21 N•m

SST

Gasket

(2) Using the pressure gauge for turbo actuator, supply air at
250 kPa to the SST and keep the condition for more than
60 seconds to see if leakage occurs from the nozzle
leakage pipe ASSY No.1.
Caution:
Make sure to observe the specified air pressure. If the air
pressure is too high, air will leak to the high pressure side.
Note:
• Coat the connecting area of the nozzle leakage pipe ASSY
No.1 with engine oil and check that no foam is produced.
• Make sure that the needle on the pressure gauge for the
turbo actuator does not go down.
(3) Remove SST and gasket.
[Point 5]
Note:
Insert the nozzle holder seal into the cylinder head cover ASSY until its end touches the surface.
[Point 6]
Installation:
Cylinder head cover
Topside Install the cylinder head cover ASSY.
1. Install the nozzle holder gasket as shown in the illustration.
Caution:
• Keep the nozzle holder gasket leveled.
• Do not put foreign matter, such as chip and sand, to the lip.
2. Install the cylinder head cover gasket.
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3-10

3. Apply FIPG to the areas shown in the illustration.

FIPG:
Toyota Genuine Seal Packing Black, Three Bond 1280E or
FIPG equivalent
Application
Caution:
• Clean and degrease the installation surface.
• After the application of FIPG, installation should be
performed within 3 minutes and tightening within 15
minutes.
• Do not put FIPG to the camshaft thrust groove.
• After the installation, leave the unit for two hours without
filling engine oil.
4. Tighten the bolts and nuts in the order shown in the illustration.
(8) (2) (4) (6) Tighten them again in the order shown in the illustration and
(12) install the cylinder head cover ASSY.
(10)

(9) (11)
(5) (3) (1) (7)
1KD_RM.book 11 ページ ２０１３年９月２７日　金曜日　午後１２時４７分

3-11

SUPPLY PUMP
REMOVAL, INSPECTION AND INSTALLATION
 Non-reusable parts T = N•m

T = 31 to 39

T = 4 to 6

T = 31 to 39

9
䃂
䃂 T = 22
T = 17 to 25
T = 61 to 67

䃂 䃂 T=9

6 䃂
5
8
7
T = 25 to 37

Removal and Installation Procedures

The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Timing belt See page 2-7  
2 Fuel inlet pipe S/A [Point 10]
3 Fuel hose No.1 [Point 9]
4 Fuel hose No.2 [Point 8]
5 Camshaft timing pulley flange No.2 [Point 7]
6 Pump drive shaft pulley
7 Supply pump ASSY [Point 1] [Point 6]
8 Suction control valve ASSY [Point 2] [Point 5]
9 Fuel temperature sensor [Point 3] [Point 4]
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3-12

Caution:
• When the supply pump ASSY is replaced, the fuel inlet pipe S/A needs to be replaced as well.
• When installing pipes, clean the connected areas and remove foreign matters.
• Be sure to clean the working area before replacing the suction control valve ASSY and fuel temperature
sensor.
• The suction control valve ASSY and fuel temperature sensor must be replaced by clean hands without
wearing gloves.
[Point 1]
Removal:
Remove the supply pump ASSY.
1. Remove the nut.
SST 09213-76011-71, 09330-76001-71

SST

2. Loosen the two nuts.

Caution:
Do not remove the nuts.

3. Disconnect the supply pump ASSY from the supply pump drive
gear S/A.
SST 09950-76021-71
SST (09951-05010, 09952-05010, 09953-05020, 09954-05021)

4. Remove the two nuts and remove the supply pump ASSY.
Caution:
Do not drop the supply pump ASSY.
1KD_RM.book 13 ページ ２０１３年９月２７日　金曜日　午後１２時４７分

3-13

[Point 2]
Caution:
• Do not reuse the removed suction control valve ASSY or O-ring.
• Check that the O-ring is not left in the supply pump ASSY.
[Point 3]
Removal:
Remove the fuel temperature sensor.
SST 09922-76001-71

SST

[Point 4]
Installation:
Install the fuel temperature sensor.
SST SST 09922-76001-71
T = 22 N•m
When using SST with torque wrench L = 26 cm
T = 14 N•m
Note:
• The standard value for SST (effective length 137 cm) with
torque wrench L = 26 cm is given assuming that the SST
and torque wrench are used in a straight line.
• The standard value needs to be reviewed when the torque
wrench is changed to another.(See page 0-11 for the
procedure.)
[Point 5]
Installation:
Install the suction control valve ASSY.
1. Coat a new O-ring with engine oil.
Caution:
• Use a clean engine oil.
• Check the O-ring groove and O-ring for foreign matter or
damage.

2. Attach the guide pins for installing the suction control valve
Guide pin ASSY to the bolt holes.
Note:
• The guide pins can be attached by hand lightly.
• The guide pins are used to install the suction control valve
ASSY vertically.
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3-14

3. Coat the O-ring attached at the end of the suction control valve
ASSY with engine oil.
Caution:
Use a clean engine oil.

4. As shown in the illustration, insert the suction control valve

Guide pin ASSY into the supply pump ASSY vertically along the guide
pins.
Caution:
• Check the installation surfaces of the supply pump ASSY
and suction control valve ASSY for foreign matter or
damage.
• Insert the suction control valve ASSY straight.
• Do not squeeze the O-ring. If it happens, replace the O-ring
Supply pump ASSY with new one. Insert the suction control valve ASSY until it
touches the supply pump ASSY.
5. Remove the guide pins while holding the suction control valve
ASSY.
6. Temporarily tighten the two fixing bolts evenly by hand until the
contact surfaces of suction control valve ASSY and supply
pump ASSY come into contact.
7. Fully tighten the two fixing bolts of suction control valve ASSY.
[Point 6]
Key groove
Installation:
Install the supply pump ASSY.
1. Install the O-ring to the supply pump ASSY.
2. Mount the supply pump ASSY to the timing gear case by
aligning with the key groove on the supply pump drive gear S/
A.
3. While supporting the supply pump ASSY by hand, push the
supply pump drive gear S/A to the rear of the vehicle to bring it
into close contact with the supply pump drive shaft.
4. Temporarily attach the supply pump ASSY with nut.
1KD_RM.book 15 ページ ２０１３年９月２７日　金曜日　午後１２時４７分

3-15

5. Fix the crankshaft pulley S/A.

SST 09213-76011-71, 09330-76001-71
6. Attach the nut through the O-ring.
7. Fully tighten the fixing nut of the supply pump ASSY.

SST

[Point 7]
Installation:
Move the pump drive shaft pulley back and forth and measure the
thrust clearance of the supply pump drive shaft.
Standard: 0.15 to 0.55 mm (0.0059 to 0.0217 in.)
Note:
If the pulley does not move backward or forward, remove the
timing gear cover and install it again. (See page 2-41 for the
procedure.)

[Point 8]
Installation:
Direct the claw of clip as shown in the illustration.

Back
side
Outside

90°

[Point 9]
Installation:
Direct the claw of clip as shown in the illustration.

Back
side
Outside

[Point 10]
Caution:
• Fully tighten the injection pipe clamp before tightening the
fuel inlet pipe S/A fully.
• Make sure that the fuel inlet pipe S/A is held by the injection
pipe clamp properly and there is no looseness between
them.