CYLINDER HEAD 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.


  1. INSTALL CYLINDER HEAD GASKET

    A01E1XTE01

    1. Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

    2. A01DWGGE01

      Measure the piston protrusion of each cylinder at 2 points as shown in the illustration.

    3. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

      Piston protrusion
      0.005 to 0.255 mm (0.0002 to 0.0100 in.)

      Tech Tips

      When the removing piston and connecting rod assembly: If the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    4. A01DXBTE01

      Select a new cylinder head gasket.

      Tech Tips

      New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.

      New installed cylinder head gasket thickness
      Mark Thickness
      A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      E 1.00 to 1.10 mm (0.0394 to 0.0433 in.)

      1. Select the largest piston protrusion value from the measurements made. Then select a new appropriate gasket according to the table below.

        Use gasket size
        Gasket Size Piston Protrusion
        Use A 0.005 to 0.054 mm (0.0002 to 0.0021 in.)
        Use B 0.055 to 0.104 mm (0.0022 to 0.0041 in.)
        Use C 0.105 to 0.154 mm (0.0041 to 0.0061 in.)
        Use D 0.155 to 0.204 mm (0.0061 to 0.0080 in.)
        Use E 0.205 to 0.255 mm (0.0081 to 0.0100 in.)
    5. A01E1R6E01

      Place the cylinder head on the cylinder block.


      1. Place the cylinder head gasket on the cylinder block.

        Note

        Be careful of the installation direction.

      2. Place the cylinder head on the cylinder head gasket.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01E12RE01

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • If any bolt is broken or deformed, replace it.


    1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

    2. Install and uniformly tighten the 18 cylinder head bolts, in several passes in the sequence shown in the illustration.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt length A
      110 mm (4.33 in.)
      Bolt length B
      167 mm (6.57 in.)

      If any of the cylinder head bolts does not meet the torque specification, replace it.

    3. A01DYXOE02

      Mark the front of the cylinder head bolts with paint.

    4. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration above.

    5. Finally, tighten the cylinder head bolts by an additional 90°.

    6. Check that the painted marks are now facing rearward.

  3. INSTALL CAMSHAFT

    A01E2S9E01

    1. Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    2. A01DXL7E02

      Install the camshaft.


      1. Apply MP grease to the thrust portion of the camshaft.

      2. Place the camshaft on the cylinder head, facing the key groove upward.

      3. A01DV15E01

        Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.

    3. A01DYANE03

      Remove any old packing (FIPG) material from the camshaft bearing cap.

    4. Apply seal packing to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note


      • Do not allow FIPG to contact the oil passage of the bearing cap.

      • After applying FIPG, install the camshaft bearing caps within 3 minutes and fasten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after the installation.


      1. A01E2XHE01

        Install the 5 bearing caps in their proper locations.

      2. A01E0JJE02

        Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

      3. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

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

    5. Install the camshaft oil seal.

  4. INSPECT VALVE CLEARANCE

    A01DX9JE02

    1. Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (Cold)
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

    2. Turn the crankshaft 360° to set the No. 4 cylinder to TDC / compression.

    3. A01E0RDE02

      Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

  5. ADJUST VALVE CLEARANCE


    1. Adjust the valve clearance Click here.

  6. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install the injector, holder clamp, washer and bolt in their original positions.


    1. A01DYB9E01

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a small amount of clean engine oil to 4 new O-rings.

    3. A01E0HXE06

      Install an O-ring to each injector as shown in the illustration.

    4. Insert the 4 injectors into the cylinder head.

      Note


      • Insert the injector until it touches the nozzle sheet 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.

    5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.

    6. A01DWZ6E04

      Temporarily install 4 new washers and the 4 nozzle holder clamps with the 4 bolts.

      Note

      Make sure that the washers face the direction shown in the illustration.

      Tech Tips

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

      Note


      • A01DV3XE04

        The fork portion of the nozzle holder clamp must be set to the injector.

      • Before tightening the bolts, check that the nozzle holder clamp is set properly.

      • To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in the following step.

      • When tightening the bolts, pay attention not to tilt the bolt and clamp.

      • Do not reuse the washer.

      • If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

    7. Temporarily install the 4 injection pipes with the union nuts.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A01E2T3E01

      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.

    9. A01DVA2E03

      Set the leakage pipe and 5 new gaskets in place.

    10. Apply a small amount of oil to the 4 hollow screws and union bolt.

    11. Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

    12. Tighten the 4 holder clamp bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    13. A01DVZRE06

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

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

      Note

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

    14. 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.

    15. Remove the 4 injection pipes.

  7. INSPECT FOR FUEL LEAK


    1. A01E0SLE03

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


      1. 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)
        SST
        09280-00010
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      2. Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

      3. A01DX5HE01

        Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 100 kPa (1.0 kgf/cm2, 14.5 psi) of pressure for 60 seconds to check that no bubbles form.

        SST
        09992-00242

        Note

        Before checking the leakage, be sure to remove the ball and spring in the check valve.

      4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

      5. Remove SST, No. 2 nozzle leakage pipe and gasket.

        Note

        Never reinstall the disassembled union bolt on the engine.

  8. INSTALL CYLINDER BLOCK INSULATOR (w/ EGR Cooler)


    1. A01E2IC

      Install the block insulator to the head.

  9. INSTALL NO. 2 TIMING BELT COVER

    A01E1J8E01

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

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

      Note

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

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

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

  10. INSTALL CAMSHAFT TIMING PULLEY

    A01DV9RE01

    1. Install the camshaft timing pulley.

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

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DZAXE01

      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.

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

    3. A01E1YSE02

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

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

      Note


      • Remove any oil from the contact surface.

      • Install the belt cover within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the seal packing.

    4. A01DZGHE01

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

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

  12. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new nozzle holder seals.

  13. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. Install the timing belt idler and new washer with the bolt.

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

  14. INSTALL TIMING BELT


    1. A01E2G9E02

      Check that the timing marks are aligned as shown in the illustration.

      Tech Tips

      If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

      Note


      • The engine should be cold.

      • When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

    2. Using a 10 mm hexagon wrench, install the timing belt idler pulley and new washer with the bolt.

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

    3. Check that the idler pulley moves smoothly.

      If it does not move smoothly, check the idler sub-assembly and washer.

    4. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

    5. A01E2YJE01

      Place the tensioner upright. Then set the press to the top of the tensioner.

      Note


      • Do not scratch or deform the rod end.

      • Press in the tensioner rod upward.

      • Protect the tip of the push rod with a cloth in order to prevent damage.

    6. Using a press, slowly push in the push rod using 981 to 9800 N (100 to 999 kgf, 220 to 2203 lbf) of force.

      Note

      Do not impose a load of over 9800 N (100 to 999 kgf, 2203 lbf) to the push rod.

    7. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    8. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

    9. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the 2 bolts and install the tensioner.

    10. A01DZUHE01

      Remove the 1.5 mm hexagon wrench from the tensioner.

    11. A01DWQTE02

      Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

  15. INSTALL NO. 1 TIMING BELT COVER


    1. Install the timing belt cover with the 6 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Install the wire harness clamp.

    3. Install the water hose clamp with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  16. INSTALL INTAKE MANIFOLD (w/ EGR Cooler)


    1. Install the intake manifold Click here.

  17. INSTALL INTAKE MANIFOLD (w/o EGR Cooler)


    1. A01E1QPE01

      Install a new gasket and the manifold to the cylinder head withe the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  18. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY (w/o EGR Cooler)


    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 }

    4. Connect the 3 fuel hoses.

  19. INSTALL NO. 4 INJECTION PIPE


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

    2. 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 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. A01DW74E03

      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 in.*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.

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

      Torque:
      35 N*m  { 357 kgf*cm, 26 in.*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.

  20. INSTALL NO. 1, NO. 2 AND NO. 4 INJECTION PIPE (w/o EGR Cooler)

    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. A01DYQLE04

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

    2. 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.

    3. A01E32TE03

      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 in.*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.

    4. 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 in.*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.

  21. CONNECT WIRE HARNESS (w/o EGR Cooler)

  22. INSTALL MANIFOLD STAY (w/o EGR Cooler)


    1. A01DWQ8E01

      Install the manifold stay with the 2 bolts.

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

      Tech Tips

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

  23. INSTALL GLOW PLUG ASSEMBLY


    1. w/ EGR Cooler:

      Install the glow plug assembly Click here.

    2. w/ EGR System:

      Install the glow plug assembly Click here.

    3. w/o EGR System:

      Install the glow plug assembly Click here.

  24. INSTALL EXHAUST MANIFOLD

    A01DZAUE01

    1. w/ EGR Cooler:

      Install a new gasket, manifold, 8 new collars and 8 spacers to the cylinder head with 8 new nuts.

    2. w/o EGR Cooler:

      Install a new gasket, manifold and 8 spacers to the cylinder head with 8 new nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note

      Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

  25. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. w/ EGR Cooler:

      Install the turbocharger sub-assembly Click here.

    2. w/o EGR Cooler:

      Install the turbocharger sub-assembly Click here.

  26. INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. Install the bracket with the 2 bolts.

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

  27. INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)


    1. A01DZH8E02

      Install the viscous with magnet clutch heater with the 2 bolt.

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

    2. Connect the connect.

  28. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


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

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

  29. INSTALL COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Install the cooler compressor with the 4 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  30. INSTALL FAN PULLEY


    1. Install the fan pulley with the 4 nuts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  31. INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Install the shroud together with the coupling fan between the radiator and engine component.

      Note

      Be careful not to damage the radiator core.

    3. Install the fluid coupling fan to the fan pulley with the 4 nuts.

      Tighten the nuts as much as possible by hand.

    4. A01DZVX

      Attach the shroud's claws to the radiator.

    5. Install the shroud with the 2 bolts.

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

    6. Install the drive belt Click here.

    7. Tighten the 4 nuts of the fluid coupling fan.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    8. A01DVHL

      Install the radiator reservoir with the 2 bolts.

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

    9. Connect the No. 1 and No. 2 water by-pass hoses to the tank upper and lower.

    10. A01DZXC

      Install the oil reservoir with the 3 bolts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

  32. ADD FUEL

  33. TIGHTEN FUEL TANK CAP ASSEMBLY

  34. ADD ENGINE OIL

  35. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      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. Start the engine.

      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. A01DVKYE03

      Enter the following menus: Powertrain / Engine and ECT / 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.

      A01DYT1E05

      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 and ECT / 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 and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  37. PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes Click here.

    2. Perform pilot quantity learning Click here.

  38. PERFORM INITIALIZATION


    1. Perform initialization of the crank time compensation reset function Click here.

  39. CHECK FOR ENGINE OIL LEAKS

  40. INSPECT FOR FUEL LEAK

    A01E2N9E01

    CAUTION:


    • During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

    • During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped 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 push 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.

  41. CHECK OIL LEVEL