012 - 000 - 000-2GD-FTV Fuel

FUEL SYSTEM > PRECAUTION
IGNITION SWITCH EXPRESSIONS
a. The type of ignition switch used on this model differs depending on the specifications of the vehicle.
The expressions listed in the table below are used in this section.
Ignition Switch Engine Switch

Expression
(Position) (Condition)
Ignition Switch off LOCK Off (Lock)
Ignition Switch ACC ACC On (ACC)
Ignition Switch ON ON On (IG)
Engine Start START On (Start)
-1-
2GD-FTV FUEL > FUEL SYSTEM
*3
*1 *9
- *13 *2 - *4
- *14 - *17
*6
- *18 *8
*10
*12
*11 - *16
*5 - *7
- *15
A344946C01
*1 COMMON RAIL *2 FUEL FILTER
*3 FUEL INJECTOR *4 FUEL SENDER GAUGE ASSEMBLY
*5 FUEL SUPPLY PUMP *6 FUEL TANK CAP
*7 EDU RELAY *8 FUEL TANK ASSEMBLY
*9 VENT TUBE ASSEMBLY *10 ECM
ENGINE ROOM RELAY BLOCK AND
INSTRUMENT PANEL JUNCTION BLOCK
*11 JUNCTION BLOCK ASSEMBLY *12
- EFI MAIN NO. 1 FUSE
- EDU FUSE
*13 FUEL PRESSURE SENSOR *14 PRESSURE DISCHARGE VALVE
*15 PRE-STROKE CONTROL VALVE *16 EFI MAIN NO. 1 RELAY
-2-
*17 LEVEL WARNING SWITCH *18 GLOGGING SWITCH
*1
A353405C01
*1 COMBINATION METER ASSEMBLY - -
-3-
FUEL SYSTEM > SYSTEM DIAGRAM
FUEL FLOW DIAGRAM
*1 *2 *3
*4
*6
*5
*7
*8
*9
A339105C01
-4-
*1 Fuel Pressure Sensor *2 Common Rail Assembly
*3 Pressure Discharge Valve *4 Fuel Supply Pump Assembly
*5 Pre-Stroke Control Valve *6 Injector Assembly
*7 ECM *8 Fuel Filter Assembly
*9 Fuel Tank Assembly - -
High Pressure Fuel Return Fuel
Suction Fuel - -
FUEL SYSTEM WIRING DIAGRAM
-5-
6
2 1 C38 #1D+
C48
No. 1 Fuel Injector 3
PCV+ C39 1 2
+B PCV
x1
7
Pre-Stroke Control Valve
C38 #1D-
4
1
2 1 PCV- C39
C38 #2D+
C49
No. 2 Fuel Injector
2
C38 #2D-
7
2 1 28
C39 #3D+ 6
C50 VCM C40 VC
No. 3 Fuel Injector
25
3
8 E2S C41 E2S
C39 #3D- 33
1
VCS C41 VCS
5 26
2 1 2
C38 #4D+ PCR2 C41 PR2
C51
No. 4 Fuel Injector 18
5
PCR1 C40 PR
4
19
C38 #4D- 4
E2M C40 E2
z2
Fuel Pressure Sensor
ECM
A347093E01
-6-
2
2
PRV+ C39 COM3
1
1
PRV- C39 RLV
5
3 5 z3
C40 +BD1 Pressure Discharge Valve
EDU
4
2 1 C40 +BD2
from Battery 2
E04 C41
EDU
3
E1D1 C38
5
E1D2 C39
14
G49 MREL 3
ME01 C41
2
G50 +B 3
EFI-MAIN NO. 1 E01 C40
3
EFI-MAIN NO. 1 G50 +B2
4
from Battery 4 E02 C41
G50 +B3
1
E1 C41
ECM
A347094E01
-7-
3 25
FR FR
1 24
FV FV
2 26
FE FE&B
O6
Fuel Sender Gauge Assembly
4 13
E + 3 S
A40
Level Warning Switch Assembly G8
Combination Meter
A347095E01
-8-
FUEL SYSTEM > ON-VEHICLE INSPECTION
1. INSPECT FOR FUEL LEAK

CAUTION:
• During Active Test mode, the engine speed becomes high and the combustion noise
becomes loud, so pay attention.
• During Active Test mode, the fuel pressure becomes high. Be extremely careful not to
expose your eyes, hands, or body to escaping fuel.
HINT:
Using the GTS to perform Active Tests allow relays, VSVs, actuators and other items to be operated
without removing any parts. This non-intrusive functional inspection can be very useful because
intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests
early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while
performing Active Tests.
a. 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.
b. 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.
c. Disconnect the return hose from the common rail assembly.
d. Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail assembly.
e. Connect the GTS to the DLC3.
f. Start the engine and turn the GTS on.
g. Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.
Powertrain > Engine and ECT > Active Test
Tester Display
Test the Fuel Leak
Execute
h. 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.
i. 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.
If there is fuel leakage, repair or replace parts as necessary.
j. Reconnect the return hose to the common rail assembly.
-9-
2. CHECK PRESSURE DISCHARGE VALVE
HINT:
• This is the procedure for troubleshooting fuel pressure control malfunctions and
combustion problems.
• Malfunctions can be determined by checking the fuel pressure when performing a fuel
cut and operating the pressure discharge valve with the GTS.
• During "Pressure Discharge Valve Check", the GTS measures the fuel pressure while the
engine is running, after the engine is stopped, and after the pressure discharge valve
operates.
a. Connect the GTS to the DLC3.
b. Turn the ignition switch to ON.
c. Turn the GTS on.

NOTICE:
The following conditions must be met:
• Engine is idling.
• Vehicle is stopped.
• Fuel pressure is not extremely high (below 100000 kPa).
• Fuel pressure is not extremely low (higher than 26000 kPa).
• Fuel pressure sensor is normal.
• Battery voltage is higher than 8 V.
HINT:
When the common rail pressure is unstable, the fuel pressure may decrease to a level where the
test cannot be performed. In this situation, wait until the common rail pressure meets the test
condition, and then perform the test.
d. Enter the following menus: Powertrain / Engine and ECT / Utility / Pressure Discharge Valve Check.
Powertrain > Engine and ECT > Utility
Tester Display
Pressure Discharge Valve Check
Execute
e. Press "Next".
f. Press "Next" again to proceed.
g. Select the check type for "Valve Check for Graph".
1. Press "Next" again to proceed.
- 10 -
2. Press "Start" again to proceed.
*a
*b
*c
*d *e
A267385C03
*a Engine Speed *b Fuel Pressure
When "Start" is pressed, the pressure
*c Pressure Discharge Valve *d
discharge valve check begins.
If "Save" is pressed after the pressure
discharge valve check, the data
*e - -
recorded during the valve check can be
saved.
h. Select the check type "Close to Open Check" or "Always Closed Check".
HINT:
• "Close to Open Check" opens the pressure discharge valve after the engine stops.
• "Always Closed Check" holds the pressure discharge valve closed during the check.
1. Press "Next".
i. Perform troubleshooting based on the measurement results.
OK:
0.5 MPa or less
HINT:
- 11 -
• During "Close to Open Check", if there is no large change in fuel pressure when the
pressure discharge valve is closed while the engine is running and after the engine
is stopped, and if the value is 0 MPa when the pressure discharge valve is open, the
system is normal.
• Perform "Always Closed Check" if the value is not 0 MPa when the pressure
discharge valve is open during "Close to Open Check". If the results are the same as
during "Close to Open Check", there is a pressure discharge valve operation
malfunction.
• If a large amount of fuel is leaking, the fuel pressure decreases when the engine is
stopped. However, the condition of the pressure discharge valve can still be
determined by comparing the measurement results of "Close to Open Check" and
"Always Closed Check".
- 12 -
*a
*h
*b
*h
*c
*i
*j
*d
*k
*k
*e
*j
*l
*f
*k
*m
*l
*g
*k
*n
*o
A271188C03
Fuel Press Fuel Press
*a *b
(Always Closed Check) (Close to Open Check)
*c Engine Speed *d Fuel Cut Operation Signal
Pressure Discharge Valve Operation Pressure Discharge Valve Operation
*e *f
(Prohibition) (Always Closed Check)
Pressure Discharge Valve Operation
*g *h 0 MPa
(Close to Open Check)
*i 0 rpm *j On
*k Off *l Closed (on)
- 13 -
*m Open (on) *n Fuel Press Recorded
Pressure Discharge Valve Operation
*o - -
Start
3. BLEED AIR FROM FUEL SYSTEM
a. 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:
• Hand pump pumping speed: Max. 2
strokes/ sec.
• The hand pump must be pushed with a

full stroke during pumping.
• When the fuel pressure at the supply

pump inlet port reaches a saturated
pressure, the hand pump resistance
increases. A339106
• If pumping is interrupted during the air

bleeding process, fuel in the fuel line may return to the fuel tank assembly.
Continue pumping until the hand pump resistance increases.
• 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 assembly and fuel
filter assembly, the hand pump may be malfunctioning, or the vehicle may have run
out of fuel.
• If air bleeding using the hand pump is incomplete, the common rail assembly
pressure does not rise to the pressure range necessary for normal use, and the
engine cannot be started.
b. Check if the engine starts.

NOTICE:
• Even if air bleeding using the hand pump has been completed, the starter assembly
may need to be cranked for 10 seconds or more to start the engine.
• Do not crank the engine continuously for more than 20 seconds. The battery may be
discharged.
• Use a fully-charged battery.
i. When the engine can be started, proceed to the next step.
ii. 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.
c. Turn the ignition switch off.
d. Connect the GTS to the DLC3.
e. Turn the ignition switch to ON and turn the GTS on.
- 14 -
f. Clear the DTCs.
(Click here ENGINE CONTROL (2GD-FTV) > ECD SYSTEM > DTC CHECK / CLEAR )
g. Start the engine.*1
h. Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2
Powertrain > Engine and ECT > Trouble Codes
Execute
i. Perform the following test 5th times with on/off intervals of 10 seconds: Active Test / Test the Fuel
Leak.*3
j. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.
*d *e *f
*g
*b
*a
*c
*g *h
*i
A271189C03
*a Active Test Operation *b ON
*c OFF *d 1st time
*e 2nd time *f 5th time
*g 10 seconds *h 3 minutes
*i 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 assembly drops below the target fuel pressure when the Active
Test is off, but this is normal and does not indicate a pump malfunction.
k. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
Execute
l. Read Current DTCs.
m. Clear the DTCs.

HINT:
- 15 -
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.
n. Repeat steps *1 to *3.
o. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
Execute
p. Read Current DTCs.
OK:
No DTCs are output.
4. CHECK FUEL SYSTEM WARNING LIGHT AND DRAIN WATER
a. w/ Multi-information Display:
Check the fuel system warning is displayed on the multi-information display, replace the fuel filter
element assembly (Click here FUEL (2GD-FTV) > FUEL FILTER > REPLACEMENT ) or drain the water
in the fuel filter assembly.
b. w/o Multi-information Display:

Check the fuel system warning light in the combination meter assembly and either replace the fuel
filter element assembly (Click here FUEL (2GD-FTV) > FUEL FILTER > REPLACEMENT ) or drain the
water in the fuel filter assembly based on the instructions shown in the illustration.
*a *b *c
*d
*h *j
*e
*f
*d
*i *k
*e
*g
A257158C02
*a Fuel System Warning Light *b Fuel Filter Condition
*c Necessary Procedure *d On
*e Off *f Illuminate
*g Blinking *h Clogged
Replace the Fuel Filter Element
*i Water Level Warning *j
Assembly
*k Drain the Water - -
c. Drain water.
- 16 -
i. Detach the clamp and disconnect the No. 1
fuel hose from the No. 2 fuel pipe clamp.
A339765
ii. Disconnect the clamp and slide the lead wire

as shown in the illustration to remove it.
A339642N01
iii. Disconnect the level warning switch connector.
A339529
- 17 -
iv. Slide the fuel filter assembly and lift it up.
A339643
v. Connect a hose to the drain cock. Place the

other end of the hose into a container under
the drain cock.
vi. Loosen the drain cock to drain water.
vii. Operate the hand pump until fuel begins to

run out.
viii. Tighten the drain cock by hand.

NOTICE:
Do not use any tools in this procedure.
A347060
ix. Slide the fuel filter assembly to install it.
x. Connect the level warning switch connector.
A339669
- 18 -
xi. Attach the clamp and slide the lead wire as
shown in the illustration to install it.
A339641N01
xii. Attach the clamp and connect the No. 1 fuel

hose to the No. 2 fuel pipe clamp. *2
HINT:
Make sure that the paint mark of the No. 1 *a
fuel hose is positioned as shown in the
illustration.
*1
A339766C01
*1 No. 1 Fuel Hose
*2 No. 2 Fuel Pipe Clamp
*a Paint Mark
- 19 -
2GD-FTV FUEL > FUEL INJECTOR
10 (102, 7)
8.4 (86, 74 in.*lbf)
*7
● *14 *1
12 (122, 9)
*13
x4
x4
12 (122, 9)
*5
*8
21 (214, 15)
*12
*2 *11
x4
x4 *10
● *15
x4 ● *6
x4
● *9
x4 x4
40 (408, 30)
x4 *3
40 (408, 30) 31 (316, 23)*
31 (316, 23)*
*4
*3 *4
40 (408, 30)
31 (316, 23)*
A339107C01
*1 HARNESS BRACKET *2 INJECTOR ASSEMBLY
*3 NO. 1 INJECTION PIPE SUB-ASSEMBLY *4 NO. 2 INJECTION PIPE SUB-ASSEMBLY
- 20 -
*5 NOZZLE HOLDER GASKET *6 NOZZLE LEAKAGE PIPE ASSEMBLY
*7 WIRING HARNESS CLAMP BRACKET *8 NO. 5 FUEL HOSE
*9 INJECTION NOZZLE SEAT *10 NOZZLE HOLDER CLAMP
*11 WASHER *12 NOZZLE HOLDER CLAMP BOLT
*13 UNION BOLT *14 GASKET
*15 O-RING - -
Tightening torque for "Major areas
involving basic vehicle performance
N*m (kgf*cm, ft.*lbf): Specified torque
such as moving/turning/stopping" :
N*m (kgf*cm, ft.*lbf)
* For use with SST ● Non-reusable part
Engine oil - -
- 21 -
FUEL INJECTOR > ON-VEHICLE INSPECTION
1. CHECK INJECTOR ASSEMBLY
a. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or
higher.
b. Allow the engine to idle for 1 minute or more.
c. Connect the GTS to the DLC3.
d. Turn the GTS on.
e. Enter the following menus: Powertrain / Engine and ECT / Data List / Injection Volume and Injector
Feedback Val. #1 to #4.
Powertrain > Engine and ECT > Data List
Tester Display
Injection Volume
Injection Feedback Val #1
Execute
f. Read the values when the engine is idling.
g. Check that the "Injector Feedback Val. #1 to #4" values are within the specification.
Standard:
Tester Display Engine Condition Specified Condition
Injection Volume Idling 3 to 10 mm3/st
Injector Feedback Val. #1
Idling -3.0 to 3.0 mm3/st
If the result is not as specified, replace the fuel injector assembly.
2. CHECK INJECTOR COMPENSATION CODE

HINT:
If the injector compensation code is not correctly registered, it may cause malfunctions.
a. Read the injector compensation code.

Click here ENGINE CONTROL (2GD-FTV) > ECD SYSTEM > REGISTRATION > INPUT INJECTOR
COMPENSATION CODE(S) INTO ECM
b. Check that the compensation code of the installed injector assembly is the same as the code
registered in the ECM. If the code is not the same, register the injector compensation code on the
injector assembly.
Click here ENGINE CONTROL (2GD-FTV) > ECD SYSTEM > REGISTRATION
- 22 -
FUEL INJECTOR > REMOVAL
The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed
after parts are removed, installed, or replaced during the engine assembly removal/installation are shown
below.
Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or Effects/Inoperative when not
Necessary Procedures Link
Procedure Performed
ENGINE
w/ Stop and Start System: Drive the vehicle until stop CONTROL (2GD-
Battery terminal is and start control is permitted FTV) > ECD
Stop and start system
disconnected/ (approximately 5 to 40 SYSTEM >
reconnected minutes)
PRECAUTION
ENGINE
CONTROL (2GD-
• Injector compensation
Replacement of injector FTV) > ECD
code registration Engine starting
assembly SYSTEM >
• Pilot quantity learning
REGISTRATION
NOTICE:
• When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-
assembly, No. 2 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) • No. 1 injection pipe sub-assembly
• Common rail assembly • No. 2 injection pipe sub-assembly
• Cylinder head sub-assembly
• Supply pump assembly
• Common rail assembly
• No. 1 injection pipe sub-assembly
• Cylinder block sub-assembly
• Fuel inlet pipe sub-assembly
• Cylinder head gasket
• Timing chain case assembly
• After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly
and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.
• The injector assembly is a precision instrument. Do not use the injector assembly if it is
struck or dropped.
• Make sure foreign matter does not enter the fuel path.
1. 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 here INTRODUCTION > REPAIR INSTRUCTION > PRECAUTION
- 23 -
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click here INTRODUCTION > REPAIR INSTRUCTION > INITIALIZATION
3. REMOVE EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE

ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY
Click here EMISSION CONTROL (2GD-FTV) > EGR COOLER > REMOVAL
4. CHECK INJECTOR COMPENSATION CODE

Click here FUEL (2GD-FTV) > FUEL INJECTOR > ON-VEHICLE INSPECTION > CHECK INJECTOR
COMPENSATION CODE
5. REMOVE WIRING HARNESS CLAMP BRACKET
a. Disconnect the pressure discharge valve connector

from the common rail assembly.
b. Remove the bolt and wiring harness clamp bracket

from the cylinder head cover sub-assembly.
A339108
6. REMOVE HARNESS BRACKET
a. Remove the bolt and harness bracket.
A339109
7. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY
- 24 -
a. Slide the clamp and disconnect the No. 5 fuel hose
from the nozzle leakage pipe assembly.
b. Remove the 4 union bolts and 4 gaskets.
c. Remove the bolt and nozzle leakage pipe

assembly.
A339110
8. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

NOTICE:
After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with
electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector
inlets with electrical tape or plastic bags.
a. Using SST, loosen the No. 1 and No. 2 injection

pipe sub-assemblies and 8 union nuts of the fuel
injector assembly side and common rail assembly
side.
SST
09245-11010 SST
A352787E01
b. Remove the 2 No. 1 injection pipe sub-assemblies

and 2 No. 2 injection pipe sub-assemblies.
NOTICE:
When removing the No. 1 injection pipe sub-
assembly and No. 2 injection pipe sub-assembly,
store the injector assemblies in the correct order
so that they can be returned to their original
locations when reassembling.
A339111
- 25 -
9. REMOVE INJECTOR ASSEMBLY
a. Remove the 4 nozzle holder clamp bolts, 4 washers

and 4 nozzle holder clamps.
b. Remove the 4 fuel injector assemblies and 4

injection nozzle seats from the cylinder head sub-
assembly.
NOTICE:
When removing the injector assembly, store the
injector assemblies in the correct order so that
they can be returned to their original locations
when reassembling.
c. Remove the O-ring from each injector assembly.

A344925
10. REMOVE NOZZLE HOLDER GASKET
a. Remove the 4 nozzle holder gaskets from the

cylinder head cover sub-assembly.
A344926
- 26 -
FUEL INJECTOR > INSPECTION
1. INSPECT INJECTOR ASSEMBLY
a. Inspect the injector assembly.
i. Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Tester Connection Condition Specified Condition
1-2 20°C (68°F) 0.52 to 0.66 Ω
HINT:
The temperature indicated in "Condition" is the temperature of the injector assembly.
If the result is not as specified, replace the injector assembly.
- 27 -
FUEL INJECTOR > INSTALLATION
NOTICE:
new ones.
• The injector assembly is a precision instrument. Do not use the injector assembly if it is
struck or dropped.
1. INSTALL NOZZLE HOLDER GASKET
a. Install 4 new nozzle holder gaskets to the cylinder head cover sub-assembly.
2. TEMPORARILY INSTALL INJECTOR ASSEMBLY

NOTICE:
Before installing the injector assembly, check for carbon, foreign matter, etc. on the seal surfaces of the
cylinder head sub-assembly and injector assembly. If there is foreign matter, remove it before installing
the injector assembly.
a. Install 4 new injection nozzle seats to the cylinder head sub-assembly.
b. Apply a light coat of engine oil to the O-ring on each injector assembly.
c. Install a new O-ring to each injector assembly.
d. Install the 4 injector assemblies to the cylinder

head sub-assembly.
NOTICE:
Fit the injector assembly to the injection nozzle *1
seats.
A344927C01
*1 O-Ring
- 28 -
e. Install the nozzle holder clamps and washers as
shown in the illustration.
NOTICE:
Pay attention to the mounting orientation
(beveled edge) of the washer.
*1
f. Temporarily install the nozzle holder clamp bolts.
NOTICE:
When temporarily installing the nozzle holder
clamp bolt to the No. 1 nozzle holder clamp,
make sure that the bolt and clamp are not at an
angle.
A344928C01
HINT:
*1 Washer
Apply a light coat of engine oil to the threads of
the nozzle holder clamp bolts.
3. TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-

ASSEMBLY
a. Temporarily install the 2 No. 2 injection pipe sub-assemblies 4 union nuts.
b. Temporarily install the 2 No. 1 injection pipe sub-assemblies 4 union nuts.
4. TIGHTEN INJECTOR ASSEMBLY
a. Tighten the 4 nozzle holder clamp bolts.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
5. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
a. Using SST, tighten the No. 1 and No. 2 injection

pipe sub-assemblies 8 union nuts.
SST
09245-11010
*a
Torque:
Specified tightening torque
40 N*m (408 kgf*cm, 30 ft.*lbf)
SST
HINT:
• Calculate the torque wrench reading
when changing the fulcrum length of
the torque wrench.
A347062C01
*a Torque Wrench Fulcrum Length
- 29 -
• When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum
length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)
6. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY
a. Temporarily install the nozzle leakage pipe

assembly and 4 new gaskets with the 4 union bolts 4 3 2
1
and bolt.
b. Tighten the 4 union bolts and bolt in the order 5

shown in the illustration.
Torque:
12 N*m (122 kgf*cm, 9 ft.*lbf)
c. Connect the No. 5 fuel hose to the nozzle leakage

pipe assembly.
A339110E01
7. INSTALL HARNESS BRACKET
a. Install the harness bracket with the bolt.
Torque:
8.4 N*m (86 kgf*cm, 74 in.*lbf)
8. INSTALL WIRING HARNESS CLAMP BRACKET
a. Install the wiring harness clamp bracket with bolt to the cylinder head cover sub-assembly.
Torque:
b. Connect the pressure discharge valve connector to the common rail assembly.
9. INSTALL EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE

Click here EMISSION CONTROL (2GD-FTV) > EGR COOLER > INSTALLATION
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
11. PERFORM REGISTRATION
a. Perform registration of injector compensation codes.
- 30 -
Click here ENGINE CONTROL (2GD-FTV) > ECD SYSTEM > REGISTRATION > INPUT INJECTOR
COMPENSATION CODE(S) INTO ECM
b. Perform registration of pilot quantity learning.

Click here ENGINE CONTROL (2GD-FTV) > ECD SYSTEM > REGISTRATION > PILOT QUANTITY
LEARNING

Click here FUEL (2GD-FTV) > FUEL SYSTEM > ON-VEHICLE INSPECTION > BLEED AIR FROM FUEL
SYSTEM

Click here FUEL (2GD-FTV) > FUEL SYSTEM > ON-VEHICLE INSPECTION > INSPECT FOR FUEL LEAK
- 31 -
2GD-FTV FUEL > FUEL SUPPLY PUMP
5.0 (51, 44 in.*lbf)
x2 *7
*12
23 (235, 17)
*9 *6
x4
*13
6.5 (66, 58 in.*lbf)
*10 6.5 (66, 58 in.*lbf) *5

x2
*11
8.0 (82, 71 in.*lbf)
*1 *4
*A *2 4.5 (46, 40 in.*lbf)
*8
x3
*3
28 (286, 21)
A347072C01
*A for 4WD and Pre-Runner - -
*1 FAN SHROUD *2 NO. 1 ENGINE UNDER COVER
- 32 -
*3 NO. 1 OIL RESERVOIR BRACKET *4 NO. 1 RADIATOR HOSE
*5 NO. 2 AIR TUBE *6 NO. 4 AIR HOSE
*7 RADIATOR RESERVE TANK ASSEMBLY *8 VANE PUMP OIL RESERVOIR ASSEMBLY
*9 FAN AND GENERATOR V BELT *10 FAN PULLEY
*11 FLUID COUPLING ASSEMBLY *12 NO. 1 WATER BY-PASS HOSE
*13 VACUUM HOSE - -
N*m (kgf*cm, ft.*lbf): Specified torque - -
- 33 -
*7
21 (214, 15)
x3
10 (102, 7)
x3
*6
137 (1397, 101)

● *9
*8
*3
*4
● *10
x3 *5
21 (214, 15)
*1
*2
A347055C01
FUEL INJECTION PUMP COVER SUB-
*1 *2 FUEL PUMP MOTOR WIRE
ASSEMBLY
*3 SUPPLY PUMP ASSEMBLY *4 NO. 1 FUEL HOSE
*5 NO. 2 FUEL HOSE *6 TIMING CHAIN COVER PLATE
- 34 -
*7 V-RIBBED BELT TENSIONER ASSEMBLY *8 SUPPLY PUMP SHAFT NUT
*9 GASKET *10 O-RING
● Non-reusable part Engine oil
- 35 -
FUEL SUPPLY PUMP > REMOVAL
below.

Procedure Performed
w/ Stop and Start System: Drive the vehicle until stop INTRODUCTION
Battery terminal is and start control is permitted > REPAIR
Stop and start system INSTRUCTION >
disconnected/ (approximately 5 to 40
reconnected minutes) PRECAUTION
NOTICE:
new ones.
• The supply pump assembly is a precision instrument. Do not use the supply pump
assembly if it is struck or dropped.
• Hold the supply pump assembly itself during removal and installation. Do not hold the
pre-stroke control valve or fuel pipe, etc.
1. PRECAUTION
NOTICE:

NOTICE:
- 36 -
3. REMOVE INTAKE MANIFOLD
Click here INTAKE / EXHAUST (2TR-FE) > INTAKE MANIFOLD > REMOVAL
4. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

Click here ENGINE MECHANICAL (2GD-FTV) > ENGINE ASSEMBLY > REMOVAL > REMOVE NO. 1 ENGINE
UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)
5. REMOVE NO. 4 AIR HOSE

Click here COOLING (2GD-FTV) > RADIATOR > REMOVAL > REMOVE NO. 4 AIR HOSE
6. REMOVE NO. 2 AIR TUBE

Click here COOLING (2GD-FTV) > RADIATOR > REMOVAL > REMOVE NO. 2 AIR TUBE
7. REMOVE NO. 1 RADIATOR HOSE

Click here COOLING (2GD-FTV) > RADIATOR > REMOVAL > REMOVE NO. 1 RADIATOR HOSE
8. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

Click here COOLING (2GD-FTV) > RADIATOR > REMOVAL > DISCONNECT VANE PUMP OIL RESERVOIR
ASSEMBLY
9. REMOVE NO. 1 OIL RESERVOIR BRACKET

Click here COOLING (2GD-FTV) > RADIATOR > REMOVAL > REMOVE NO. 1 OIL RESERVOIR BRACKET
10. REMOVE RADIATOR RESERVE TANK ASSEMBLY

Click here COOLING (2GD-FTV) > RADIATOR > REMOVAL > REMOVE RADIATOR RESERVOIR
11. REMOVE FAN SHROUD

Click here COOLING (2GD-FTV) > RADIATOR > REMOVAL > REMOVE FAN SHROUD
12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

Click here ENGINE MECHANICAL (2GD-FTV) > ENGINE UNIT > REMOVAL > REMOVE V-RIBBED BELT
TENSIONER ASSEMBLY
13. REMOVE NO. 2 FUEL HOSE
- 37 -
a. Slide the 2 clips and remove the No. 2 fuel hose
from the supply pump assembly and No. 3 nozzle
leakage pipe assembly.
A344931
a. Slide the 2 clips and remove the No. 1 fuel hose

from the supply pump assembly and No. 2 fuel
pipe.
A344932
15. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY
a. Remove the fuel injection pump cover sub-

assembly from the supply pump assembly.
A344933
16. REMOVE FUEL PUMP MOTOR WIRE
- 38 -
a. Disconnect the fuel pump motor wire connector.
b. Detach the clamp and remove the fuel pump motor

wire.
A344934
17. REMOVE TIMING CHAIN COVER PLATE
a. Remove the 3 bolts and timing chain cover plate.
b. Remove the gasket.
A344936
18. REMOVE SUPPLY PUMP ASSEMBLY

NOTICE:
• Do not hold the supply pump assembly by
the parts indicated by the arrows in the
illustration.
• With SST set, do not turn the crankshaft

more than a half rotation.
A347307
- 39 -
a. Align the timing mark of the crankshaft pulley sub-
assembly and timing chain cover by rotating the
crankshaft clockwise.
*a
A349352C01
*a Timing Mark
b. Using SST, hold the crankshaft pulley assembly

and loosen the fuel supply pump shaft nut.
SST
09213-58014 (91551-80840)
09330-00021
NOTICE:
Do not excessively loosen the supply pump shaft
SST
nut, otherwise SST cannot be installed.
HINT: SST
*a
Rotate the supply pump shaft nut once to loosen
it. A344937C01
*a Hold
Turn
c. Loosen the 3 nuts from the supply pump assembly.

NOTICE:
Do not completely remove the nuts. Otherwise,
the supply pump assembly may fall off.
A347057
- 40 -
d. Install SST with 3 bolts.
SST
09241-11010
Torque:
NOTICE:
Install SST with the bolts included with SST.
SST
A344938E01
HINT:
• Make sure that the installation direction
of SST is as shown in the illustration. *a
• Align the hexagonal portion of SST with

the supply pump shaft nut to install
SST.
*b
*c
A347063C01
*a Engine Front Side
*b Engine Rear Side
*c SST Hexagonal Portion
- 41 -
e. Install the handle to SST. While holding the
crankshaft pulley assembly in place with the
crankshaft holding tool, turn the handle in the
counterclockwise direction to disconnect the supply
pump assembly.
SST
09213-58014 (91551-80840)
SST
09330-00021 SST
09241-11010
SST
f. Remove the 3 nuts and supply pump assembly *a
from the timing chain case assembly. A344939C01
*a Hold
Turn
g. Remove the O-ring from the supply pump

assembly.
A347064
- 42 -
FUEL SUPPLY PUMP > INSPECTION
1. INSPECT SUPPLY PUMP ASSEMBLY
a. Inspect the pre-stroke control valve assembly.
Tester Connection Condition Specified Condition
1-2 20°C (68°F) 0.42 to 0.52 Ω
HINT:
The temperature indicated in "Condition" is the temperature of the pre-stroke control valve.
If the result is not as specified, replace the supply pump assembly.
- 43 -
FUEL SUPPLY PUMP > INSTALLATION
NOTICE:
new ones.
• The supply pump assembly is a precision instrument. Do not use the supply pump
• Hold the supply pump assembly itself during removal and installation. Do not hold the
pre-stroke control valve or fuel pipe, etc.
1. INSTALL SUPPLY PUMP ASSEMBLY

NOTICE:
• Do not hold the supply pump assembly by
the parts indicated by the arrows in the
illustration.
• With SST set, do not turn the crankshaft

more than a half rotation.
a. Apply a light coat of engine oil to a new O-ring.
b. Install the O-ring to the supply pump assembly.
A347307
- 44 -
c. 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.
*a
A347065C01
*a Groove
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.
*b
*a
6°
A343559C02
*a Supply Pump Shaft Key
*b Upper Side
- 45 -
d. Using SST, tighten clockwise the supply pump
assembly, and then temporarily install the 3 fuel
supply pump fixing nuts.
SST
09213-58014 (91551-80840)
SST
09330-00021
09241-11010
SST
*a
A347066C01
*a Hold
Turn
e. 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. A
A344940E01
f. Remove SST and the 3 set bolts.
SST
A344938E01
- 46 -
g. Using SST, hold the crankshaft pulley sub-
assembly and tighten the set nut.
Torque:
137 N*m (1397 kgf*cm, 101 ft.*lbf)
SST
*a
A347061C01
*a Hold
Turn
2. INSTALL TIMING CHAIN COVER PLATE
a. Install the timing chain cover plate and new gasket with the 3 bolts.
Torque:
NOTICE:
Do not install the timing chain cover plate with the bolts included with SST.
3. INSTALL FUEL PUMP MOTOR WIRE
a. Attach the clamp and install the fuel pump motor wire.
b. Connect the fuel pump motor wire connector.
4. INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY
a. Install the fuel injection pump cover sub-assembly to the supply pump assembly.
5. INSTALL NO. 2 FUEL HOSE
a. 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.
a. Install the No. 1 fuel hose to the supply pump assembly and No. 2 fuel pipe, and slide the 2 clamps
to secure it.
- 47 -
7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Click here ENGINE MECHANICAL (2GD-FTV) > ENGINE UNIT > INSTALLATION > INSTALL V-RIBBED BELT
TENSIONER ASSEMBLY
8. INSTALL FAN SHROUD

Click here COOLING (2GD-FTV) > RADIATOR > INSTALLATION > INSTALL FAN SHROUD
9. INSTALL RADIATOR RESERVOIR

Click here COOLING (2GD-FTV) > RADIATOR > INSTALLATION > INSTALL RADIATOR RESERVOIR
10. INSTALL NO. 1 OIL RESERVOIR BRACKET

Click here COOLING (2GD-FTV) > RADIATOR > INSTALLATION > INSTALL NO. 1 OIL RESERVOIR
BRACKET
11. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

Click here COOLING (2GD-FTV) > RADIATOR > INSTALLATION > CONNECT VANE PUMP OIL RESERVOIR
ASSEMBLY
12. INSTALL NO. 1 RADIATOR HOSE

Click here COOLING (2GD-FTV) > RADIATOR > INSTALLATION > INSTALL NO. 1 RADIATOR HOSE
13. INSTALL NO. 2 AIR TUBE

Click here COOLING (2GD-FTV) > RADIATOR > INSTALLATION > INSTALL NO. 2 AIR TUBE
14. INSTALL NO. 4 AIR HOSE

Click here COOLING (2GD-FTV) > RADIATOR > INSTALLATION > INSTALL NO. 4 AIR HOSE
15. INSTALL INTAKE MANIFOLD

Click here INTAKE / EXHAUST (2GD-FTV) > INTAKE MANIFOLD > INSTALLATION

NOTICE:


19. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)
Click here ENGINE MECHANICAL (2GD-FTV) > ENGINE ASSEMBLY > INSTALLATION > INSTALL NO. 1
ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)
- 48 -
2GD-FTV FUEL > COMMON RAIL
*5
10 (102, 7)
*7
*1
*6 21 (214, 15)
x2
40 (408, 30)
31 (316, 23)*
*3
*4
*3
*4 40 (408, 30)
10 (102, 7) 31 (316, 23)*
40 (408, 30)
● *9 31 (316, 23)*
10 (102, 7) *2
48 (489, 35)
41 (418, 30)*
● *8
A347056C01
*1 COMMON RAIL ASSEMBLY *2 FUEL INLET PIPE SUB-ASSEMBLY
*3 NO. 1 INJECTION PIPE SUB-ASSEMBLY *4 NO. 2 INJECTION PIPE SUB-ASSEMBLY
*5 NO. 4 FUEL HOSE *6 WIRING HARNESS CLAMP BRACKET
*7 WIRE HARNESS *8 NO. 1 INJECTION PIPE CLAMP
*9 NO. 2 INJECTION PIPE CLAMP - -
* For use with SST or union nut wrench ● Non-reusable part
- 49 -
COMMON RAIL > REMOVAL
below.

Procedure Performed
w/ Stop and Start System: Drive the vehicle until stop INTRODUCTION
Battery terminal is and start control is permitted > REPAIR
Stop and start system INSTRUCTION >
disconnected/ (approximately 5 to 40
reconnected minutes) PRECAUTION
NOTICE:
new ones.
• The common rail assembly is a precision instrument. Do not use the common rail
• Hold the common rail assembly itself during removal and installation. Do not hold the
pressure discharge valve or fuel pressure sensor, etc.
1. PRECAUTION
NOTICE:

NOTICE:
- 50 -
3. REMOVE EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE
Click here EMISSION CONTROL (2GD-FTV) > EGR COOLER > REMOVAL
4. REMOVE WIRING HARNESS CLAMP BRACKET

Click here FUEL (2GD-FTV) > FUEL INJECTOR > REMOVAL > REMOVE WIRING HARNESS CLAMP BRACKET
5. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

Click here FUEL (2GD-FTV) > FUEL INJECTOR > REMOVAL > REMOVE NO. 1 AND NO. 2 INJECTION PIPE
SUB-ASSEMBLY
6. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

Click here INTAKE / EXHAUST (2GD-FTV) > INTAKE MANIFOLD > REMOVAL > REMOVE FUEL INLET PIPE
SUB-ASSEMBLY
a. Slide the clamp and disconnect the No. 4 fuel hose

from the common rail assembly.
A344943
8. REMOVE COMMON RAIL ASSEMBLY
a. Detach the wire harness clamp.
b. Disconnect the fuel pressure sensor connector from

the common rail assembly.
A344944
- 51 -
c. Remove the 2 nuts and common rail assembly.
NOTICE:
Do not remove the pressure discharge valve or
fuel pressure sensor.
A344945
- 52 -
COMMON RAIL > INSPECTION
1. INSPECT COMMON RAIL ASSEMBLY
a. Inspect the fuel pressure sensor.

*a PR2
i. Measure the resistance according to the
value(s) in the table below. E2S VCS
Specified
Tester Connection Condition
Condition
5 (PR) - 4 (E2) 16.4 kΩ or less VC E2
2 (PR2) - 3 (E2S) 16.4 kΩ or less
25°C (77°F)
6 (VC) - 5 (PR) 3 kΩ or less PR
1 (VCS) - 2 (PR2) 3 kΩ or less
If the result is not as specified, replace the A114886C01

common rail assembly. Component without harness connected
*a
(Fuel Pressure Sensor)
b. Inspect the pressure discharge valve.
Specified
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.
- 53 -
COMMON RAIL > INSTALLATION
NOTICE:
new ones.
Fuel inlet pipe sub-assembly
• The common rail assembly is a precision instrument. Do not use the common rail
• Hold the common rail assembly itself during removal and installation. Do not hold the
pressure discharge valve or fuel pressure sensor, etc.
1. INSTALL COMMON RAIL ASSEMBLY
a. Install the common rail assembly with the 2 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.
a. Connect the No. 4 fuel hose to the common rail assembly, and slide the clamp to secure it.
3. TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-

ASSEMBLY
Click here FUEL (2GD-FTV) > FUEL INJECTOR > INSTALLATION > TEMPORARILY INSTALL NO. 1 AND NO.
2 INJECTION PIPE SUB-ASSEMBLY
4. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

Click here FUEL (2GD-FTV) > FUEL INJECTOR > INSTALLATION > TIGHTEN NO. 1 AND NO. 2 INJECTION
PIPE SUB-ASSEMBLY
- 54 -
5. INSTALL FUEL INLET PIPE SUB-ASSEMBLY
Click here INTAKE / EXHAUST (2GD-FTV) > INTAKE MANIFOLD > INSTALLATION > INSTALL FUEL INLET
PIPE SUB-ASSEMBLY
6. INSTALL WIRING HARNESS CLAMP BRACKET

Click here FUEL (2GD-FTV) > FUEL INJECTOR > INSTALLATION > INSTALL WIRING HARNESS CLAMP
BRACKET
7. INSTALL EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE

Click here EMISSION CONTROL (2GD-FTV) > EGR COOLER > INSTALLATION

NOTICE:

SYSTEM

- 55 -
2GD-FTV FUEL > FUEL FILTER
*2
*6
*3
●*4
●*1
*5
A339597C01
*1 FUEL FILTER ELEMENT ASSEMBLY *2 FUEL FILTER CAP
*3 CLOGGING SWITCH CONNECTOR *4 O-RING
*5 O-RING *6 LEAD WIRE
● Non-reusable part - -
- 56 -
FUEL FILTER > INSPECTION
1. INSPECT FUEL FILTER ASSEMBLY
a. Inspect the level warning switch.

value(s) in the table below.
*a
Specified
Condition
Float at upper end
Below 1 Ω
position
3-4
Float at lower end
10 kΩ or higher
position
If the result is not as specified, replace the fuel

filter assembly.
b. Inspect the clogging switch. *b

value(s) in the table below.
Specified
Condition
1-2 20°C (68°F) Below 1 Ω

filter assembly.
A339640C01
Component without harness connected
*a
(Level Warning Switch)
*b Level Warning Switch Connector
- 57 -
FUEL FILTER > REPLACEMENT
HINT:
• When replacing the fuel filter element assembly, use TOYOTA genuine parts.
• When replacing the fuel filter element assembly, clean the fuel filter case and remove
dirt completely.
1. REMOVE FUEL FILTER ELEMENT ASSEMBLY

HINT:
Replacement of the fuel filter element assembly can be performed with the fuel filter installed to the
fuel filter bracket.
a. Detach the clamp and disconnect the No. 1 fuel

hose from the No. 2 fuel pipe clamp.
A339765
b. Disconnect the clamp and slide the lead wire as

shown in the illustration to remove it.
A339642N01
- 58 -
c. Disconnect the level warning switch connector.
A339529
d. Slide the fuel filter assembly and lift it up.
A339643
e. Connect a hose to the drain cock. Place the other

end of the hose into a container under the drain
cock.
f. Loosen the drain cock to drain fuel.
g. Tighten the drain cock by hand.
h. Disconnect a hose from the drain cock.
A339526
- 59 -
i. Disconnet the clogging switch connector.
A339530
j. Using a screwdriver as a lever, loosen the fastener

nut until it can be loosened by hand.
A339527
k. Fully loosen the fastener nut by hand.
A339528
- 60 -
l. To remove the fuel filter cap, pull up one side of
the fuel filter cap, and then lift it off.
m. Remove the fuel filter element assembly from the

fuel filter case.
n. Remove the O-ring from the fuel filter case. *1
A339532C01
*1 O-ring
o. Attach the clamp and connect the No. 1 fuel hose

to the No. 2 fuel pipe clamp. *2
HINT:
Make sure that the paint mark of the No. 1 fuel *a
hose is positioned as shown in the illustration.
*1
A339766C01
*1 No. 1 Fuel Hose
*a Paint Mark
2. INSTALL FUEL FILTER ELEMENT ASSEMBLY
a. Install a new O-ring to the fuel filter case.
b. Install the fuel filter element assembly to the fuel *2

filter case.
*1
A339533C01
*1 O-ring
*2 Fuel Filter Element Assembly
- 61 -
c. Align the mark on the fuel filter cap and the mark
on the fuel filter case.
A339534
d. Push the fuel filter cap onto the fuel filter case by
hand.
Standard clearance (A):

1.5 mm (0.0590 in.) or less
HINT:
The clearance between the fuel filter cap and fuel
filter case should be even around the entire
circumference of the fuel filter cap and fuel filter
case.
A339535N01
- 62 -
e. Turn the fastener nut until a "click" sound is heard.
HINT:
Just before the marks of the fuel filter case and
nut align, the fastener nut will become more
difficult to turn. Use a screwdriver as a lever to
turn the fastener nut.
f. Measure the distance between the marks on the

fuel filter cap and fuel filter case, and the clearance
between the fuel filter cap and fuel filter case.
Standard distance (A):

1.0 mm (0.0393 in.) or more
Standard clearance (B):

1.0 mm (0.0393 in.) or less
A339536N01
g. Slide the fuel filter assembly to install it.
h. Connect the level warning switch connector.
A339669
- 63 -
i. Attach the clamp and slide the lead wire as shown
in the illustration to install it.
A339641N01
j. Attach the clamp and connect the No. 1 fuel hose

to the No. 2 fuel pipe clamp. *2
HINT:
Make sure that the paint mark of the No. 1 fuel *a
hose is positioned as shown in the illustration.
*1
A339766C01
*1 No. 1 Fuel Hose
*a Paint Mark
3. RESET FUEL SYSTEM WARNING LIGHT
a. Turn the ignition switch to ON.
- 64 -
b. After turning the ignition switch to ON, connect the
level warning switch connector no sooner than 3
seconds have passed but no later than 60 seconds
have passed.
c. Check that the combination meter's fuel system

warning light turns off.
A339670

SYSTEM

- 65 -
2GD-FTV FUEL > FUEL TANK(for Long Wheelbase)
*5 *12
*B
*17
*1
*6
*12
*1 *13
*11
*8
●*4
●*14
*1
*9
*19
x4 *7
●*4
6.0 (61, 53 in.*lbf)
*3
*2
*15
*A
*10
*18
*20
*20
*18
*16
13 (133, 10) x5
*16 45 (459, 33)
45 (459, 33)
A339551C01
*A for 4WD and Pre-Runner *B w/ Protector
*1 FUEL HOSE *2 FUEL TANK ASSEMBLY
- 66 -
*3 FUEL TANK BREATHER HOSE *4 FUEL TANK CUSHION
*5 FUEL TANK MAIN TUBE SUB-ASSEMBLY *6 FUEL TANK RETURN TUBE
*7 FUEL TANK TO FILLER PIPE HOSE *8 FUEL TANK VENT TUBE ASSEMBLY
*9 NO. 1 FUEL TANK HEAT INSULATOR *10 NO. 1 FUEL TANK PROTECTOR
*11 NO. 3 FUEL TUBE CLAMP *12 TUBE JOINT CLIP
*13 FUEL PUMP GAUGE RETAINER *14 FUEL TANK VENT TUBE GASKET
*15 WIRE HARNESS *16 FUEL TANK BAND
*17 FUEL TANK PROTECTOR *18 CLIP
*19 FUEL TANK BOLT *20 FUEL TANK BAND PIN
● Non-reusable part - -
- 67 -
FUEL TANK(for Long Wheelbase) > REMOVAL
CAUTION:
The fuel tank assembly is very heavy. Be sure to
follow the procedure described in the repair manual,
or the fuel tank assembly may fall off the engine lifter.
A344817
1. PRECAUTION
NOTICE:

NOTICE:
3. REMOVE FUEL TANK CAP ASSEMBLY
4. REMOVE NO. 1 FUEL TANK PROTECTOR (for 4WD and Pre-Runner)
a. Remove the 5 nuts and No. 1 fuel tank protector

from fuel tank bands.
A339537
- 68 -
5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND RETURN
TUBE
a. Slide the 2 clamps and disconnect the 2 fuel hoses

from the fuel tank main tube sub-assembly and
fuel tank return tube.
A339538
6. DISCONNECT FUEL HOSE
a. Detach the clamp.
b. Disconnect the fuel hose from the fuel tank filler

pipe sub-assembly.
A339546
7. DISCONNECT FUEL TANK BREATHER HOSE
a. Detach the clamp.
b. Slide the clamp and disconnect the fuel tank

breather hose from the fuel tank filler pipe sub-
assembly.
A339545
- 69 -
8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Loosen the clamp and disconnect the fuel tank to

filler pipe hose from the fuel tank filler pipe sub-
assembly.
A339606
9. REMOVE FUEL TANK ASSEMBLY

CAUTION:
The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual,
a. Using an engine lifter and attachments, support the fuel tank assembly.
b. Remove the 2 bolts and disconnect the 2 fuel tank

bands.
c. Remove the 2 clips, 2 fuel tank band pins and 2

fuel tank bands.
HINT:
Move the fuel tank assembly just enough to
remove the fuel tank band pins.
d. Slightly lower the engine lifter.

NOTICE:
Be careful not to cut the wire harness.
A339539
- 70 -
e. Fold back approximately half of each fuel tank
cushion so that the wire harness can be removed
in the step below.
*1
*2 *3
A339541C01
*1 Fuel Tank Cushion
*2 Wire Harness
*3 Fuel Tank Assembly
f. w/ Protector:
Detach the 3 claws and remove the fuel tank
protector.
A346209
- 71 -
g. Detach the wire harness from the 5 clamps shown
in the illustration.
HINT:
Detach the claws of the clamps labeled A in the
illustration to detach the wire harness.
A
h. Disconnect the fuel sender gauge connector from A
the fuel tank vent tube assembly.
*a
A339549C01
*a Claw
10. REMOVE NO. 1 FUEL TANK HEAT INSULATOR
a. Remove the nut.
b. Using needle-nose pliers, remove the 4 fuel tank

bolts shown in the illustration, and then remove
the No. 1 fuel tank heat insulator.
1 2 3
A339544C01
- 72 -
Fuel Tank Bolt
Nut
11. REMOVE FUEL TANK CUSHION
a. Remove the 2 fuel tank cushions from the fuel tank

sub-assembly.
*1
A339560C01
12. REMOVE NO. 3 FUEL TUBE CLAMP
a. Detach the claw and remove the No. 3 fuel tube

clamp.
A346208
13. REMOVE FUEL TANK VENT TUBE ASSEMBLY
- 73 -
a. Remove the 2 tube joint clips and pull out the fuel
tank main tube sub-assembly and fuel tank return
tube from the fuel tank vent tube assembly.
A339553
NOTICE:
• Remove any dirt and foreign matter on
the fuel tube joint before performing *a
this work. *b
• Do not allow any scratches or foreign

matter on the parts when disconnecting
them, as the fuel tube joint contains the
O-rings that seal the plug.
*c *d
• Perform this work by hand. Do not use
any tools.
• Do not forcibly bend or twist the nylon

tube.
A339604C01
*a Fuel Tube Joint
• Protect the disconnected parts by
*b Fuel Tube
covering them with plastic bags and
tape after disconnecting the fuel tank *c O-Ring
main tube sub-assembly and fuel tank *d Tube Joint Clip
return tube.
b. Remove the fuel pump gauge retainer from the fuel tank assembly.
- 74 -
i. Set the 2 claws and plate of SST on the fuel
pump gauge retainer.
SST
09808-14030 (09808-01010,
09808-01030, 09808-01040)
HINT:
Securely insert the ends of SST into the
insertion points in the fuel pump gauge
retainer.
ii. While firmly pressing the claws of SST into the

retainer, tighten the bolts of the claws. *a
*b
*c
A339558C01
*a SST (Plate)
*b SST (Claw)
*c Insertion point
iii. Attach the handle of SST.
iv. While lightly pressing down on SST so it does SST

not come off the fuel pump gauge retainer,
slowly turn the handle and remove the fuel
NOTICE:
• Do not use any tools other than
SST, such as a screwdriver, etc.
• Do not use excessive force when

pressing down on SST, as the fuel
pump gauge retainer will place
excessive force on the fuel tank A339559N02
vent tube assembly and fuel pump
gauge retainer and be difficult to
remove, and parts may be damaged.
• Be sure to keep the handle level when turning it, as SST may slip off the fuel
pump gauge retainer if the handle is turned at an angle with excessive force.
• Do not use an impact wrench or turn the handle with excessive force, as parts
may be damaged.
• If SST slips off the fuel pump gauge retainer, loosen the bolts and reattach SST
to the fuel pump gauge retainer.
c. Remove the fuel tank vent tube assembly from the fuel tank sub-assembly.
NOTICE:
- 75 -
Be careful not to bend the arm of the fuel sender gauge assembly.
d. Remove the fuel tank vent tube gasket from the

fuel tank sub-assembly.
A339566
14. REMOVE FUEL HOSE
a. Remove the fuel hose from the fuel tank

evaporation tube sub-assembly.
A339603
15. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Loosen the clamp and remove the fuel tank to filler

pipe hose from the fuel tank sub-assembly.
A339554
- 76 -
FUEL TANK(for Long Wheelbase) > INSTALLATION
1. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install the fuel tank to filler pipe hose to the fuel

tank assembly, and tighten the clamp to secure
the hose.
HINT: *a
Make sure the clamp is oriented as shown in the
illustration.
*b
120°
A349937C02
*a Protrusion
*b Paint Mark (White)
2. INSTALL FUEL HOSE
a. Install the fuel hose to the fuel tank evaporation tube sub-assembly.
3. INSTALL FUEL TANK VENT TUBE ASSEMBLY
a. Apply a light coat of diesel fuel or grease to a new fuel tank vent tube gasket, and install it to the
fuel tank sub-assembly.
b. Install the fuel tank vent tube assembly to the fuel tank sub-assembly.
NOTICE:
- 77 -
c. Align the protrusions of the fuel tank vent tube
*a
assembly with the holes in the fuel tank sub-
assembly.
d. While pressing down on the fuel tank vent tube

assembly, temporarily install the fuel pump gauge
retainer.
*a
A346230C02
*a Protrusion
Hole
e. Set the 2 claws and plate of SST on the fuel pump

gauge retainer.
SST
09808-14030 (09808-01010, 09808-01030,
09808-01040)
HINT:
Securely insert the ends of SST into the insertion
points in the fuel pump gauge retainer.
f. While firmly pressing the claws of SST into the *a

insertion points in the fuel pump gauge retainer,
tighten the bolts of the claws.
g. Attach the handle of SST.

*b
*c
A346231C01
*a SST (Plate)
*b SST (Claw)
*c Insertion Point
- 78 -
h. Using SST, rotate the fuel pump gauge retainer so
that the protrusions of the fuel pump gauge
retainer are aligned with the grooves in the fuel
tank sub-assembly to install the fuel tank vent
tube assembly to the fuel tank sub-assembly.
NOTICE:
• Do not use any tools other than SST,
such as a screwdriver, etc.

pressing down on SST, as the fuel pump
gauge retainer will place excessive
force on the fuel tank vent tube
assembly and be difficult to remove,
and parts may be damaged.
• Be sure to keep the handle level when

turning it, as SST may slip off the
retainer if the handle is turned at an
angle with excessive force.
*a *a
• Do not use an impact wrench or turn
the handle with excessive force, as
parts may be damaged.
• If SST slips off the fuel pump gauge *b

retainer, loosen the bolts and reattach
SST to the fuel pump gauge retainer.
A346232C01
*a Alignment Mark
*b Groove
Turn
Front of Vehicle
i. Insert the fuel tank main tube sub-assembly and fuel tank return tube into the plugs of the fuel tank
vent tube assembly and fix them in place with the 2 tube joint clips.
NOTICE:
- 79 -
• Check that there are no scratches or
foreign objects on the connecting parts.
• Check that the fuel tube joints are

inserted securely.
• Check that the tube joint clips are on

the collars of the fuel tube joints.
• After installing the tube joint clips,

check that the fuel tube joints cannot
be pulled off. *a
• Be careful not to damage any clips. *b

If a clip is damaged, replace it.
*d *c
*f *g *e
*e
A339671C01
*a Fuel Tube Joint
*b Tube Joint Clip
*c O-Ring
*d Fuel Tank Vent Tube Assembly
*e Collar
*f CORRECT
*g INCORRECT
4. INSTALL NO. 3 FUEL TUBE CLAMP
a. Attach the claw to install the No. 3 fuel tube clamp.
5. INSTALL FUEL TANK CUSHION
a. Install the 2 new fuel tank cushions to the fuel tank sub-assembly.
6. INSTALL NO. 1 FUEL TANK HEAT INSULATOR
a. Install the No. 1 fuel tank heat insulator with the 4 fuel tank bolts and nut.
Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)
- 80 -
7. INSTALL FUEL TANK ASSEMBLY
CAUTION:
a. Set the fuel tank sub-assembly on an engine lifter and raise the fuel tank sub-assembly.
NOTICE:
Do not allow the fuel tank sub-assembly to contact the vehicle, especially the differential.
b. Fold back approximately half of each fuel tank

cushion so that the wire harness can be installed in
the step below.
c. Attach the wire harness to the 5 clamps and

connect the fuel sender gauge connector.
NOTICE:
d. Install the 2 fuel tank bands with the 2 fuel tank

band pins and 2 clips.
e. Install the 2 fuel tank bands with the 2 bolts.
Torque:
45 N*m (459 kgf*cm, 33 ft.*lbf)
*1
*2 *3
A339541C01
*2 Wire Harness
8. CONNECT FUEL TANK TO FILLER PIPE HOSE
- 81 -
a. Connect the fuel tank to filler pipe hose to the fuel
tank filler pipe sub-assembly, and tighten the
clamp to secure the hose.
HINT:
*b
illustration. *d *c
*a
55° 70°
A349936C02
*a Protrusion
*b Paint Mark (Yellow)
*c 0 to 3 mm (0 to 0.118 in.)
*d 2 to 7 mm (0.0787 to 0.276 in.)
9. CONNECT FUEL TANK BREATHER HOSE
a. Connect the fuel tank breather hose to the fuel

tank filler pipe sub-assembly, and slide the clamp
to secure the hose.
HINT:
illustration.
b. Attach the fuel tank breather hose to the clamp. *a
*b
120°
A349935C02
*a Paint Mark
*b Top of Vehicle
- 82 -
10. CONNECT FUEL HOSE
a. Connect the fuel hose to the fuel tank filler pipe sub-assembly.
b. Attach the clamp.
11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK
RETURN TUBE
a. Connect the 2 fuel hoses to the fuel tank main tube sub-assembly and fuel tank return tube, and
slide the 2 clamps to secure the hoses.
12. INSTALL NO. 1 FUEL TANK PROTECTOR (for 4WD and Pre-Runner)
a. Install the fuel tank protector to the fuel tank sub-assembly with the 5 nuts.
Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)
13. INSTALL FUEL TANK CAP ASSEMBLY

NOTICE:

SYSTEM

- 83 -
2GD-FTV FUEL > FUEL TANK(for Short Wheelbase)
*4 *17
*18
*5
*17
*18 *16
*7
*9
●*2
*10
●*14
x3 ●*3
*6
*8
●*3
*2
*1
*12
*13 *11
*13
*12
*15
*11 45 (459, 33)
45 (459, 33)
A339564C01
*1 FUEL TANK ASSEMBLY *2 FUEL TANK BREATHER HOSE
*3 FUEL TANK CUSHION *4 FUEL TANK MAIN TUBE SUB-ASSEMBLY
- 84 -
*5 FUEL TANK RETURN TUBE *6 FUEL TANK TO FILLER PIPE HOSE
NO. 1 EVAPORATION TUBE SUB-
*7 FUEL TANK VENT TUBE ASSEMBLY *8
ASSEMBLY
*9 NO. 1 FUEL TANK HEAT INSULATOR *10 FUEL TANK BOLT
*11 FUEL TANK BAND *12 CLIP
*13 FUEL TANK BAND PIN *14 FUEL TANK VENT TUBE GASKET
*15 WIRE HARNESS *16 FUEL PUMP GAUGE RETAINER
*17 TUBE JOINT CLIP *18 FUEL HOSE
● Non-reusable part
- 85 -
FUEL TANK(for Short Wheelbase) > REMOVAL
CAUTION:
The fuel tank assembly is very heavy. Be sure to
follow the procedure described in the repair manual,
A344817
1. PRECAUTION
NOTICE:

NOTICE:
3. REMOVE FUEL TANK CAP ASSEMBLY
4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK

RETURN TUBE
a. Slide the 2 clamps and disconnect the 2 fuel hoses

from the fuel tank main tube sub-assembly and
fuel tank return tube.
A339538
- 86 -
5. DISCONNECT NO. 1 EVAPORATION TUBE SUB-ASSEMBLY
a. Disconnect the No. 1 evaporation tube sub-

assembly from the fuel tank filler pipe sub-
assembly.
A339548
6. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Loosen the clamp and disconnect the fuel tank to

filler pipe hose from the fuel tank filler pipe sub-
assembly.
A339547
7. DISCONNECT FUEL TANK BREATHER HOSE
a. Slide the clamp and disconnect the fuel tank

breather hose from the fuel tank filler pipe sub-
assembly.
A339605
- 87 -
8. REMOVE FUEL TANK ASSEMBLY
CAUTION:
a. Using an engine lifter and attachments, support the fuel tank assembly.
b. Remove the 2 bolts and disconnect the 2 fuel tank

bands.
c. Remove the 2 clips, 2 fuel tank band pins and 2

fuel tank bands.
HINT:
Move the fuel tank just enough to remove the fuel
tank band pins.
d. Slightly lower the engine lifter.

NOTICE:
A339540
e. Fold back approximately half of each cushion so

that the wire harness can be removed in the step
below.
*1
*2 *3
A339542C01
*2 Wire Harness
- 88 -
f. Detach the wire harness from the 3 clamps shown
in the illustration.
g. Disconnect the fuel sender gauge connector from

the fuel tank vent tube assembly.
A339550
9. REMOVE NO. 1 FUEL TANK HEAT INSULATOR
a. Using needle-nose pliers, remove the 3 fuel tank

bolts shown in the illustration, and then remove
the No. 1 fuel tank heat insulator.
1 2 3
A339543C01
Fuel Tank Bolt
10. REMOVE FUEL TANK CUSHION
- 89 -
a. Remove the 2 fuel tank cushions from the fuel tank
assembly.
*1
A339679C01
a. Remove the 2 tube joint clips and pull out the fuel
tank main tube sub-assembly and fuel tank return
tube from the fuel tank vent tube assembly.
A339553
NOTICE:
• Remove any dirt and foreign matter on
the fuel tube joint before performing *a
this work. *b
• Do not allow any scratches or foreign

matter on the parts when disconnecting
them, as the fuel tube joint contains the
O-rings that seal the plug.
*c *d
• Perform this work by hand. Do not use
any tools.
• Do not forcibly bend or twist the nylon

tube.
A339604C01
*a Fuel Tube Joint
*b Fuel Tube
*c O-Ring
*d Tube Joint Clip
- 90 -
• Protect the disconnected parts by covering them with plastic bags and tape after
disconnecting the fuel tank main tube sub-assembly and fuel tank return tube.
b. Remove the fuel pump gauge retainer from fuel

tank assembly.
i. Set the 2 claws and plate of SST on the fuel

SST
09808-14030 (09808-01010,
09808-01030, 09808-01040)
HINT:
Securely insert the ends of SST into the
retainer.
*a
ii. While firmly pressing the claws of SST into the
retainer, tighten the bolts of the claws. *b
*c
A339558C01
*a SST (Plate)
*b SST (Claw)
*c Insertion Point
iii. Attach the handle of SST.
iv. While lightly pressing down on SST so it does SST

not come off the fuel pump gauge retainer,
slowly turn the handle and remove the fuel
NOTICE:
• Do not use any tools other than
SST, such as a screwdriver, etc.

pressing down on SST, as the fuel
pump gauge retainer will place
excessive force on the fuel tank A339559N02
vent tube assembly and fuel pump
gauge retainer and be difficult to
remove, and parts may be damaged.
• Be sure to keep the handle level when turning it, as SST may slip off the fuel
pump gauge retainer if the handle is turned at an angle with excessive force.
• Do not use an impact wrench or turn the handle with excessive force, as parts
may be damaged.
- 91 -
• If SST slips off the fuel pump gauge retainer, loosen the bolts and reattach SST
to the fuel pump gauge retainer.
c. Remove the fuel tank vent tube sub-assembly from the fuel tank assembly.
NOTICE:
d. Remove the fuel tank vent tube gasket from the

fuel tank assembly.
A339566
12. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Loosen the clamp and remove the fuel tank to filler

pipe hose from the fuel tank assembly.
A339556
- 92 -
FUEL TANK(for Short Wheelbase) > INSTALLATION
1. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install the fuel tank to filler pipe hose to the fuel

tank assembly, and tighten the clamp to secure
the hose.
HINT: *a
illustration.
*b
180°
A349940C02
*a Protrusion
*b Paint Mark (Red)
a. Apply a light coat of diesel fuel or grease to a new fuel tank vent tube gasket, and install it to the
fuel tank assembly.
b. Install the fuel tank vent tube assembly to the fuel tank assembly.
NOTICE:
c. Align the protrusions of the fuel tank vent tube

*a
assembly with the holes in the fuel tank assembly.
d. While pressing down on the fuel tank vent tube

assembly, temporarily install the fuel pump gauge
retainer.
*a
A346230C02
*a Protrusion
- 93 -
Hole
e. Set the 2 claws and plate of SST on the fuel pump

gauge retainer.
SST
09808-14030 (09808-01010, 09808-01030,
09808-01040)
HINT:
Securely insert the ends of SST into the insertion
points in the fuel pump gauge retainer.
f. While firmly pressing the claws of SST into the *a

insertion points in the fuel pump gauge retainer,
tighten the bolts of the claws.
g. Attach the handle of SST.

*b
*c
A346231C01
*a SST (Plate)
*b SST (Claw)
*c Insertion Point
- 94 -
h. Using SST, rotate the fuel pump gauge retainer so
that the protrusions of the fuel pump gauge
retainer are aligned with the grooves in the fuel
tank assembly to install the fuel tank vent tube
assembly to the fuel tank assembly.
NOTICE:
• Do not use any tools other than SST,
such as a screwdriver, etc.

pressing down on SST, as the fuel pump
gauge retainer will place excessive
force on the fuel tank vent tube
assembly and be difficult to remove,
and parts may be damaged.
• Be sure to keep the handle level when

turning it, as SST may slip off the fuel
pump gauge retainer if the handle is
turned at an angle with excessive force.
*a *a
• Do not use an impact wrench or turn
the handle with excessive force, as
parts may be damaged.
• If SST slips off the fuel pump gauge *b

retainer, loosen the bolts and reattach
SST to the fuel pump gauge retainer.
A346232C01
*a Alignment Mark
*b Groove
Turn
Front of Vehicle
i. Insert the fuel tank main tube sub-assembly and fuel tank return tube into the plugs of the fuel tank
vent tube assembly and fix them in place with the 2 tube joint clips.
NOTICE:
- 95 -
• Check that there are no scratches or
foreign objects on the connecting parts.
• Check that the fuel tube joints are

inserted securely.
• Check that the tube joint clips are on

the collars of the fuel tube joints.
• After installing the tube joint clips,

check that the fuel tube joints cannot
be pulled off. *a
• Be careful not to damage any clips. *b

If a clip is damaged, replace it.
*d *c
*f *g *e
*e
A339671C01
*a Fuel Tube Joint
*b Tube Joint Clip
*c O-Ring
*d Fuel Tank Vent Tube Assembly
*e Collar
*f CORRECT
*g INCORRECT
3. INSTALL FUEL TANK CUSHION
a. Install the 2 fuel tank cushions to the fuel tank assembly.
4. INSTALL NO. 1 FUEL TANK HEAT INSULATOR
a. Install the No. 1 fuel tank heat insulator with the 3 fuel tank bolts.
5. INSTALL FUEL TANK ASSEMBLY

CAUTION:
a. Set the fuel tank assembly on an engine lifter and raise the fuel tank assembly.
NOTICE:
Do not allow the fuel tank assembly to contact the vehicle, especially the differential.
- 96 -
b. Fold back approximately half of each fuel tank
cushion so that the wire harness can be installed in
the step below.
c. Attach the wire harness to the 3 clamps and

connect the fuel sender gauge connector.
NOTICE:
d. Install the 2 fuel tank bands with the 2 fuel tank

band pins and 2 clips.
e. Install the 2 fuel tank bands with the 2 bolts.
Torque:
45 N*m (459 kgf*cm, 33 ft.*lbf)
*1
*2 *3
A339542C01
*2 Wire Harness
6. CONNECT FUEL TANK BREATHER HOSE
a. Connect the fuel tank breather hose to the fuel

tank filler pipe sub-assembly, and slide the clamp
to secure the hose.
HINT:
illustration.
*a
*b
120°
A349938C02
- 97 -
*a Paint Mark
*b Top of Vehicle
7. CONNECT FUEL TANK TO FILLER PIPE HOSE
a. Connect the fuel tank to filler pipe hose to the fuel

tank filler pipe sub-assembly, and tighten the
clamp to secure the hose.
HINT:
*b
illustration. *d *c
*a
55°
125°
A349939C02
*a Protrusion
*b Paint Mark (Yellow)
*c 0 to 3 mm (0 to 0.118 in.)
*d 2 to 7 mm (0.0787 to 0.276 in.)
8. INSTALL NO. 1 EVAPORATION TUBE SUB-ASSEMBLY
a. Connect the No. 1 evaporation tube sub-assembly to the fuel tank filler pipe sub-assembly.
9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK

RETURN TUBE
a. Connect the 2 fuel hoses to the fuel tank main tube sub-assembly and fuel tank return tube, and
slide the 2 clamps to secure the hoses.
10. INSTALL FUEL TANK CAP ASSEMBLY

NOTICE:
- 98 -
SYSTEM

- 99 -
2GD-FTV FUEL > FUEL SENDER GAUGE ASSEMBLY
*A
*2
*1
A339568C01
*A for Short wheelbase - -
*1 FUEL SENDER GAUGE ASSEMBLY *2 FUEL TANK VENT TUBE ASSEMBLY
- 100 -
*A
*2
*1
A339567C01
*A for Long wheelbase - -
*1 FUEL SENDER GAUGE ASSEMBLY *2 FUEL TANK VENT TUBE ASSEMBLY
- 101 -
FUEL SENDER GAUGE ASSEMBLY > REMOVAL

• for Short Wheelbase
Click here FUEL (2GD-FTV) > FUEL TANK (for Short Wheelbase) > REMOVAL
• for Long Wheelbase

Click here FUEL (2GD-FTV) > FUEL TANK (for Long Wheelbase) > REMOVAL
2. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.

*A
*B
A339607C01
*A for Short Wheelbase
*B for Long Wheelbase
- 102 -
b. Detach the claw and slide the fuel sender gauge
assembly upward to remove it.
A339572C01
Slide
- 103 -
FUEL SENDER GAUGE ASSEMBLY > INSPECTION
1. INSPECT FUEL SENDER GAUGE ASSEMBLY (for Short Wheelbase)
a. Check the fuel sender gauge assembly output voltage.
i. Apply 5 V between terminals 2 (FE) and 3

(FV). *a
FE
NOTICE:
• Be careful when connecting the
FV
leads, as the fuel sender gauge
assembly may be damaged if the
leads are connected to the wrong
terminals.
• Do not apply more than 6 V to

terminals 2 (FE) and 3 (FV). *b
HINT:
If a stable power supply is not available, use A339767C01
4 1.2 V nickel-metal hydride batteries or Component without harness connected
*a
equivalent. (Fuel Sender Gauge Assembly)
*b Voltage applied between terminals
ii. Measure the voltage according to the value(s)

*a
in the table below.
Standard Voltage:
Specified
Tester Connection Condition FR
Condition
Float position is F
4.25 to 4.61 V*
(upper)
1 (FR) - 2 (FE)
Float position is E FE
0.34 to 0.70 V*
(lower)
*: The output voltage changes depending

on the voltage applied to the terminals.
HINT:
• Output voltage(F) = (0.850 x
Voltage applied to terminals) to
(0.922 x Voltage applied to F
terminals)
• Output voltage(E) = (0.068 x

(0.140 x Voltage applied to
terminals)
E
sender gauge assembly.
A339574C01
Front view of wire harness connector
*a
(to Fuel Sender Gauge Assembly)
- 104 -
2. INSPECT FUEL SENDER GAUGE ASSEMBLY (for Long Wheelbase)
a. Check the fuel sender gauge assembly output voltage.
i. Apply 5 V between terminals 2 (FE) and 3

(FV). *a
FE
NOTICE:
• Be careful when connecting the
FV
leads, as the fuel sender gauge
assembly may be damaged if the
leads are connected to the wrong
terminals.
• Do not apply more than 6 V to

terminals 2 (FE) and 3 (FV). *b
HINT:
If a stable power supply is not available, use A339767C01
4 1.2 V nickel-metal hydride batteries or Component without harness connected
*a
equivalent. (Fuel Sender Gauge Assembly)
*b Voltage applied between terminals
ii. Measure the voltage according to the value(s)

*a
in the table below.
Standard Voltage:
Specified
Condition FR
Float position is F
4.25 to 4.61 V*
(upper)
1 (FR) - 2 (FE)
Float position is E FE
0.34 to 0.70 V*
(lower)
*: The output voltage changes depending

on the voltage applied to the terminals.
F
HINT:
• Output voltage(F) = (0.850 x
terminals)
• Output voltage(E) = (0.068 x

terminals)
E
sender gauge assembly.
A339573C01
Front view of wire harness connector
*a
(to Fuel Sender Gauge Assembly)
- 105 -
FUEL SENDER GAUGE ASSEMBLY > INSTALLATION
1. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Set the fuel sender gauge assembly on the fuel

tank vent tube assembly. Then slide the fuel
sender gauge downward to install it.
b. Connect the fuel sender gauge assembly

connector.
A339576C01
Slide

• for Short Wheelbase
Click here FUEL (2GD-FTV) > FUEL TANK (for Short Wheelbase) > INSTALLATION
• for Long Wheelbase

Click here FUEL (2GD-FTV) > FUEL TANK (for Long Wheelbase) > INSTALLATION
- 106 -

012 - 000 - 000-2GD-FTV Fuel

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FUEL SYSTEM > PRECAUTION

IGNITION SWITCH EXPRESSIONS

Ignition Switch Engine Switch

High Pressure Fuel Return Fuel

FUEL SYSTEM WIRING DIAGRAM

1. INSPECT FOR FUEL LEAK

c. Disconnect the return hose from the common rail assembly.

e. Connect the GTS to the DLC3.

f. Start the engine and turn the GTS on.

Powertrain > Engine and ECT > Active Test

If there is fuel leakage, repair or replace parts as necessary.

j. Reconnect the return hose to the common rail assembly.

a. Connect the GTS to the DLC3.

b. Turn the ignition switch to ON.

c. Turn the GTS on.

• Fuel pressure is not extremely high (below 100000 kPa).

• Fuel pressure is not extremely low (higher than 26000 kPa).

• Fuel pressure sensor is normal.

• Battery voltage is higher than 8 V.

Powertrain > Engine and ECT > Utility

f. Press "Next" again to proceed.

g. Select the check type for "Valve Check for Graph".

1. Press "Next" again to proceed.

i. Perform troubleshooting based on the measurement results.

3. BLEED AIR FROM FUEL SYSTEM

a. Using the hand pump mounted on the fuel filter

• The hand pump must be pushed with a

• When the fuel pressure at the supply

• If pumping is interrupted during the air

b. Check if the engine starts.

• Use a fully-charged battery.

i. When the engine can be started, proceed to the next step.

c. Turn the ignition switch off.

d. Connect the GTS to the DLC3.

e. Turn the ignition switch to ON and turn the GTS on.

g. Start the engine.*1

Powertrain > Engine and ECT > Trouble Codes

Powertrain > Engine and ECT > Trouble Codes

l. Read Current DTCs.

m. Clear the DTCs.

n. Repeat steps *1 to *3.

Powertrain > Engine and ECT > Trouble Codes

p. Read Current DTCs.

4. CHECK FUEL SYSTEM WARNING LIGHT AND DRAIN WATER

b. w/o Multi-information Display:

ii. Disconnect the clamp and slide the lead wire

iii. Disconnect the level warning switch connector.

v. Connect a hose to the drain cock. Place the

vi. Loosen the drain cock to drain water.

vii. Operate the hand pump until fuel begins to

viii. Tighten the drain cock by hand.

ix. Slide the fuel filter assembly to install it.

x. Connect the level warning switch connector.

xii. Attach the clamp and connect the No. 1 fuel

1. CHECK INJECTOR ASSEMBLY

b. Allow the engine to idle for 1 minute or more.

c. Connect the GTS to the DLC3.

d. Turn the GTS on.

Powertrain > Engine and ECT > Data List

f. Read the values when the engine is idling.

If the result is not as specified, replace the fuel injector assembly.

2. CHECK INJECTOR COMPENSATION CODE

n. Repeat steps 1 to 3.

10 6.5 (66, 58 in.lbf) *5

Nm (kgfcm, ft.*lbf): Specified torque - -