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Print-Toyota Service Information 11/3/17, 6(06 pm Print Exit 1GD-FTV FUEL COMMON RAIL COMPONENTS ILLUSTRATION *A *1 w/ DPF COMMON RAIL ASSEMBLY *2 FUEL INLET PIPE SUB-ASSEMBLY *3 NO INJECTION PIPE SUB-ASSEMBLY *4 NO INJECTION PIPE SUB-ASSEMBLY *5 NO FUEL HOSE *6 NO FUEL PIPE SUB-ASSEMBLY *7 *9 WIRING HARNESS CLAMP BRACKET NO INJECTION PIPE CLAMP *8 *10 WIRE HARNESS NO INJECTION PIPE CLAMP UNION BOLT *12 GASKET *11 https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MGQ1.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(06 pm Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf) * For use with SST or union nut wrench N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGQ1.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(06 pm Print Exit 1GD-FTV FUEL COMMON RAIL INSPECTION PROCEDURE 1.INSPECT COMMON RAIL ASSEMBLY 23810A a *a Component without harness connected (Fuel Pressure Sensor) Inspect the fuel pressure sensor i Measure the resistance according to the value(s) in the table below Standard Resistance: Tester Specified Condition Connection Condition (PR) - (E2) 16.4 kΩ or less (PR2) - (E2S) 16.4 kΩ or less (VC) - (PR) 25°C (77°F) kΩ or less (VCS) - (PR2) kΩ or less If the result is not as specified, replace the common rail assembly b Inspect the pressure discharge valve i Measure the resistance according to the value(s) in the table below Standard Resistance: Tester Specified Condition Connection Condition 1-2 20°C (68°F) 0.42 to 0.52 Ω HINT: The temperature indicated in "Condition" is the temperature of the pressure discharge valve If the result is not as specified, replace the common rail assembly © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MGPZ.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(06 pm Print Exit 1GD-FTV FUEL COMMON RAIL INSTALLATION CAUTION / NOTICE / HINT NOTICE: · When replacing the parts in the following chart (A), replace the No injection pipe sub-assembly, No injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones Replaced Parts (A) Pipes Requiring New Replacement · · · · · · · Injector assembly (including shuffling the injector assemblies between the cylinders) Common rail assembly Cylinder head sub-assembly · · No injection pipe sub-assembly No injection pipe sub-assembly · · · · · · Supply pump assembly Common rail assembly Cylinder block sub-assembly Cylinder head sub-assembly Cylinder head gasket Timing chain case assembly · · · No injection pipe sub-assembly No injection pipe sub-assembly Fuel inlet pipe sub-assembly After removing the No injection pipe sub-assembly, No injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air The common rail assembly is a precision instrument Do not use the common rail assembly if it is struck or dropped Hold the common rail assembly itself during removal and installation Do not hold the pressure discharge valve or fuel pressure sensor, etc Make sure foreign matter does not enter the fuel path PROCEDURE 1.INSTALL COMMON RAIL ASSEMBLY a Install the common rail assembly with the nuts Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) b Connect the fuel pressure sensor connector to the common rail assembly c Attach the wire harness clamp 2.INSTALL NO FUEL HOSE a 23810A 23282D Connect the No fuel hose to the common rail assembly, and slide the clamp to secure it 3.TEMPORARILY INSTALL NO AND NO INJECTION PIPE SUB-ASSEMBLY Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>INSTALLATION 4.TIGHTEN NO AND NO INJECTION PIPE SUB-ASSEMBLY https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGQ0.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(06 pm Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>INSTALLATION 5.INSTALL FUEL INLET PIPE SUB-ASSEMBLY 23804C Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>INTAKE MANIFOLD>INSTALLATION 6.INSTALL NO FUEL PIPE SUB-ASSEMBLY (w/ DPF) 23804D Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>INTAKE MANIFOLD>INSTALLATION 7.INSTALL WIRING HARNESS CLAMP BRACKET Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>INSTALLATION 8.INSTALL EGR COOLER SUB-ASSEMBLY AND NO EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY 25800 Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR COOLER>INSTALLATION 9.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION 10.BLEED AIR FROM FUEL SYSTEM Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION 11.INSPECT FOR FUEL LEAK Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGQ0.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(06 pm Print Exit 1GD-FTV FUEL COMMON RAIL REMOVAL CAUTION / NOTICE / HINT NOTICE: · When replacing the parts in the following chart (A), replace the No injection pipe sub-assembly, No injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones Replaced Parts (A) Pipes Requiring New Replacement · · · · · · · Injector assembly (including shuffling the injector assemblies between the cylinders) Common rail assembly Cylinder head sub-assembly · · No injection pipe sub-assembly No injection pipe sub-assembly · · · · · · Supply pump assembly Common rail assembly Cylinder block sub-assembly Cylinder head sub-assembly Cylinder head gasket Timing chain case assembly · · · No injection pipe sub-assembly No injection pipe sub-assembly Fuel inlet pipe sub-assembly After removing the No injection pipe sub-assembly, No injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air The common rail assembly is a precision instrument Do not use the common rail assembly if it is struck or dropped Hold the common rail assembly itself during removal and installation Do not hold the pressure discharge valve or fuel pressure sensor, etc Make sure foreign matter does not enter the fuel path PROCEDURE PRECAUTION NOTICE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION 2.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION 3.REMOVE EGR COOLER SUB-ASSEMBLY AND NO EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY 25800 Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR COOLER>REMOVAL 4.REMOVE WIRING HARNESS CLAMP BRACKET Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>REMOVAL https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGQ2.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(06 pm 5.REMOVE NO AND NO INJECTION PIPE SUB-ASSEMBLY Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>REMOVAL 6.REMOVE NO FUEL PIPE SUB-ASSEMBLY (w/ DPF) 23804D Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>INTAKE MANIFOLD>REMOVAL 7.REMOVE FUEL INLET PIPE SUB-ASSEMBLY 23804C Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>INTAKE MANIFOLD>REMOVAL 8.REMOVE NO FUEL HOSE 23282D a Slide the clamp and disconnect the No fuel hose from the common rail assembly 9.REMOVE COMMON RAIL ASSEMBLY 23810A a Detach the wire harness clamp b Disconnect the fuel pressure sensor connector from the common rail assembly https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGQ2.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(06 pm c Remove the nuts and common rail assembly NOTICE: Do not remove the pressure discharge valve or fuel pressure sensor © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGQ2.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(07 pm Print Exit 1GD-FTV FUEL FUEL FILTER COMPONENTS ILLUSTRATION *1 FUEL FILTER ELEMENT ASSEMBLY *2 FUEL FILTER CAP *3 *5 CLOGGING SWITCH CONNECTOR FUEL FILTER CASE *4 *6 O-RING LEAD WIRE ● Non-reusable part - - © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000M7RQ.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(07 pm Print Exit 1GD-FTV FUEL FUEL FILTER INSPECTION PROCEDURE 1.INSPECT FUEL FILTER ASSEMBLY 23300 a *a *b Component without harness connected (Level Warning Switch) Level Warning Switch Connector Inspect the level warning switch i Measure the resistance according to the value(s) in the table below Standard Resistance: Tester Specified Condition Connection Condition 3-4 Float at upper end position Below Ω Float at lower end position 10 kΩ or higher If the result is not as specified, replace the fuel filter assembly b Inspect the clogging switch i Measure the resistance according to the value(s) in the table below Standard Resistance: Tester Specified Condition Connection Condition https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000M7RR.html?PUB_TYPE=RM&MODE=1 Page of