FUEL INJECTOR (w/o EGR Cooler) INSTALLATION

Note

When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.
When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.
After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.

INSTALL INJECTOR ASSEMBLY

Note

Be sure to install each injector, No. 1 nozzle holder clamp, washer and bolt in its original position.

Install 4 new injection nozzle seats to the cylinder head.
Apply a small amount of clean engine oil to 4 new O-rings.
Text in Illustration

*1 New O-Ring

Install one of the O-rings to each injector as shown in the illustration.
Insert the 4 injectors into the cylinder head.
Note
- Insert the injector until it touches the injection nozzle seat surface.
- After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
- Always return an injector to the same place it was removed from.
For an injector that has been replaced with a new injector, register the injector compensation code Click here.
Temporarily install the 4 injection pipes with the union nuts.

Tech Tips

To position the injectors, loosely tighten the union nuts.
Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.

If scratches or dents are present, replace the nozzle leakage pipe assembly.

Text in Illustration
*1	New O-Ring

Text in Illustration
*1	Union Bolt
*2	Injector Hollow Screw
*3	New Gasket

Set the nozzle leakage pipe and 5 new gaskets in place.

Apply a small amount of oil to the 4 injector hollow screws and union bolt.
Temporarily install the nozzle leakage pipe with the 4 injector hollow screws and union bolt.
Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

Text in Illustration

*1 Washer

*a Downward
Note
- The fork portion of the No. 1 nozzle holder clamp must be set on the injector.
- Before tightening the bolts, check that the No. 1 nozzle holder clamps are set properly.
- When installing the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a following step.
- When tightening the bolts, be careful so as not to tilt the bolt or clamp.
- Do not reuse the washer.
Text in Illustration

*1 No. 1 Nozzle Holder Clamp

Tech Tips

Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.
Tighten the 4 holder clamp bolts.

Torque:

22 N*m { 220 kgf*cm, 16 ft.*lbf }
Remove the 4 injection pipes.
Text in Illustration

*1 Union Bolt

Tighten the 4 injector hollow screws in order from 1 to 4.

Torque:

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

Note

If an injector hollow screw is accidentally tightened beyond the torque specification, it must be replaced.
Tighten the union bolt.

Torque:

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

Note

If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

Text in Illustration
*1	Washer
*a	Downward

Text in Illustration
*1	No. 1 Nozzle Holder Clamp

INSPECT FOR FUEL LEAK

Check that there are no leaks from the nozzle leakage pipe connection.

Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

Part No.
23762-27010 (No. 2 nozzle leakage pipe)
90904-30012 (Gasket)

SST: 09280-00010

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

Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.
Install SST (turbocharger pressure gauge) to the fuel return side of the nozzle leakage pipe and maintain 100 kPa (1.0 kgf/cm², 15 psi) of pressure for 60 seconds to check that no bubbles form.

SST

09992-00242

Note

Before checking for leakage, be sure to remove the ball and spring in the check valve.
After checking for fuel leaks, wipe off the soapy water from the nozzle leakage pipe connection.
Remove SST, the No. 2 nozzle leakage pipe and gasket.

Note

Never reinstall the disassembled check valve to the engine.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Text in Illustration
*1	No. 3 Cylinder Head Cover Gasket
*2	Cylinder Head Cover

Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

Note

Do not install the No. 3 cylinder head cover gaskets at an angle.
Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

Remove any old seal packing (FIPG material) from the cylinder head.
Apply seal packing to the specific areas shown in the illustration.

Seal packing

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

Text in Illustration

Seal Packing
Note
- Remove any oil from the contact surface.
- Install the head cover within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing the seal packing.
Install a new cylinder head cover gasket and the cylinder head cover with the 10 bolts and 2 nuts.

Torque:

9.0 N*m { 92 kgf*cm, 80 in.*lbf }
Connect the ventilation hose.
Install 4 new nozzle holder seals.
Connect the 4 injector connectors and install the 3 bolts.

Torque:

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

INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
1. w/ Intercooler:
  1. Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.
  2. Temporarily install a new gasket and the union bolt.
  3. Tighten the 3 bolts and union bolt.
    
    Torque:
    
    for bolt
    
    13 N*m { 130 kgf*cm, 9 ft.*lbf }
    
    for union bolt
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. w/o Intercooler:
  1. Temporarily install the No. 2 nozzle leakage pipe with the 2 bolts.
  2. Temporarily install a new gasket and the union bolt.
  3. Tighten the 2 bolts and union bolt.
    
    Torque:
    
    for bolt
    
    13 N*m { 130 kgf*cm, 9 ft.*lbf }
    
    for union bolt
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Connect the 3 fuel hoses.
INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY
Note
- When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.
- Keep the joints of the injection pipe clean.
1. Temporarily install the No. 4 injection pipe with the union nuts.
2. w/ Intercooler:
  
  Install the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  Note
  - If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
  - Make sure that the inner rubbers of the injection pipe fit inside the clamps.
  - When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.
3. w/o Intercooler:
  
  Install the 2 bolts.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  Note
  - If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
  - Make sure that the inner rubbers of the injection pipe fit inside the clamps.
  - When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.
4. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
5. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

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

Text in Illustration
	Seal Packing

TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ Intercooler)

Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts labeled A in the illustration.

Note

Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.
Install a new gasket and the EGR valve adapter to the electric EGR control valve with the 2 bolts labeled B in the illustration.

Torque:

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

Note

Make sure the claws of the gasket face the electric EGR control valve as shown in the illustration.
Set a new gasket on the intake manifold.

Note

Make sure the claws of the gasket face the intake manifold as shown in the illustration.

Temporarily install the intake air connector to the intake manifold with the 3 bolts labeled C in the illustration.

Text in Illustration
*1	No. 2 Intake Air Connector	*2	Electric EGR Control Valve
*3	Intake Air Connector	*4	EGR Valve Adapter
*5	New Gasket	*6	Claw
*7	Intake Manifold	-	-
*a	0 to 2 threads	-	-

INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)
1. w/ Intercooler:
  1. Temporarily install the No. 1 EGR pipe and 2 new gaskets to the cylinder head and EGR valve adapter with the 2 nuts and 2 bolts.
    
    Note
    
    Make sure the claws of the gasket face the No. 1 EGR pipe as shown in the illustration.
  2. Tighten the 2 nuts labeled A.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
  3. Tighten the 2 bolts labeled B.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
    
    Text in Illustration
    
    *1 New Gasket *2 Claw
2. Text in Illustration
  
  *1 Claw
  
  w/o Intercooler:
  
  Install 2 new gaskets and the No. 1 EGR pipe with the 2 nuts and 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Tech Tips
  
  Make sure the claws of the gasket face the No. 1 EGR pipe.
TIGHTEN INTAKE AIR CONNECTOR (w/ Intercooler)
1. Tighten the 3 nuts labeled A in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 3 bolts labeled B in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration.
  
  Text in Illustration
  
  *a Front Side of Vehicle - -
INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ Intercooler)
1. w/ Intercooler:
  1. Temporarily install the No. 2 intake air connector bracket with the 3 bolts.
  2. Tighten the bolt labeled A.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  3. Tighten the 2 bolts labeled B.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. w/o Intercooler:
  
  Install the No. 2 intake air connector bracket with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)
1. w/ Intercooler:
  1. Install the electric vacuum regulating valve bracket with the 2 bolts.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  2. Install the No. 1 gas filter with gas filter bracket with the bolt.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  3. Connect the 6 vacuum hoses.
    
    Note
    
    Be sure to securely connect the vacuum hoses.
  4. Connect the 2 connectors.
2. w/o Intercooler:
  1. Install the electric vacuum regulating valve together with the bracket with the 2 bolts.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  2. Connect the 2 vacuum hoses.
  3. Connect the connector.
CONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)
1. Connect the No. 3 water by-pass pipe with wire harness with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }

Text in Illustration
*1	New Gasket	*2	Claw

Text in Illustration
*1	Claw

Text in Illustration
*a	Front Side of Vehicle	-	-

INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

Note

When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.
Keep the joints of the injection pipes clean.

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

Text in Illustration
*1	No. 2 Injection Pipe
*2	No. 2 Injection Pipe Clamp
*3	No. 3 Injection Pipe Clamp
*4	Painted Mark

w/ Intercooler:

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

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

Tech Tips

If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

Text in Illustration
*1	No. 1 Injection Pipe
*2	No. 2 Injection Pipe Clamp
*3	No. 3 Injection Pipe Clamp
*4	Painted Mark

w/o Intercooler:

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

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

Tech Tips

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

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

Torque:

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

Note

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

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

Note

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

INSTALL DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
BLEED AIR FROM FUEL SYSTEM
1. Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.
  Note
  
  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.
  
  If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
  
  If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
  
  If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.
2. Check if the engine starts.
  Note
  - Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
  - Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
  - Use a fully-charged battery.
  1. When the engine can be started, proceed to the next step.
  2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
3. Turn the ignition switch off.
4. Connect the intelligent tester to the DLC3.
5. Turn the ignition switch to ON and turn the intelligent tester on.
6. Clear the DTCs Click here.
7. Start the engine.*1
8. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.*2
9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3
10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.
  
  Tech Tips
  
  When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.
11. Enter the following menus: Powertrain / Engine / DTC.
12. Read Current DTCs.
13. Clear the DTCs Click here.
  
  Tech Tips
  
  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.
14. Repeat steps *1 to *3.
15. Enter the following menus: Powertrain / Engine / DTC.
16. Read Current DTCs.
  
  OK
  
  No DTCs are output.
PERFORM REGISTRATION
1. Perform registration of injector compensation codes Click here.
2. Perform pilot quantity learning Click here.
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.
1. 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.
2. 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.
3. Disconnect the return hose from the common rail.
4. Start the engine and check for fuel leaks from the return pipe.
  
  If there is fuel leakage, replace the common rail.
5. Connect the intelligent tester to the DLC3.
6. Start the engine and turn the intelligent tester main switch on.
7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.
8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.
9. Check that there are no leaks from any part of the fuel system.
  
  Note
  
  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.
10. Reconnect the return hose to the common rail.
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
INSPECT ENGINE OIL LEVEL
1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low and full level marks.
  
  If the oil level is low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill engine oil above the full level mark.