FUEL INJECTOR INSTALLATION

INSTALL INJECTOR ASSEMBLY
Note

Register the injector compensation code of a new fuel injector in the ECM when replacing the fuel injector. Register the injector compensation code in advance so that it can be installed in the correct position. Click here
1. Install 4 new injection nozzle seats to the cylinder head.
2. Apply a light amount of clean engine oil to 4 new O-rings.
3. Install an O-ring to each injector as shown in the illustration.
4. Install a new No. 2 cylinder head cover gasket to each injector.
5. Insert the 4 injectors into the cylinder head.
  Note
  - Check that the insertion part of the fuel injector has no foreign matter attached.
  - When reusing a fuel injector, install the same fuel injector that was removed. Otherwise, it could cause the engine to malfunction.
  - Carefully insert the fuel injector so that the O-ring is not caught between the cylinder head and the injector.
6. Temporarily install the 4 nozzle holder clamps with the 4 clamp bolts.
  
  Note
  
  Be sure to install the holder clamps and bolts in their original positions.
7. Install the 4 holder seals.
  
  Note
  
  Securely insert the tip of the holder seal into the fuel injector.
8. Temporarily install the nozzle leakage pipe assembly through 5 new gaskets by hand with the union bolt and the 4 hollow screws.
9. Temporarily tighten the union nuts of injection pipes No. 1, No. 2, No. 3 and No. 4 by hand.
10. Tighten the 4 nozzle holder clamp bolts.
  
  Torque:
  
  25 N*m { 225 kgf*cm, 18 ft.*lbf }
  
  Note
  
  After tightening the nozzle holder clamp bolts, check that the fuel injector and the nozzle holder clamp do not interfere with the valve spring.
11. Tighten the 4 hollow screws and union bolt.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL INJECTION PIPE SUB-ASSEMBLY
1. Temporarily install the 4 injection pipes with the union nuts.
2. Using SST, tighten the union nuts.
  
  SST
  
  09023-12901
  
  Torque:
  
  44 N*m { 449 kgf*cm, 33 ft.*lbf }
  
  Note
  
  Refer to the torque above when not using SST. When using SST, calculate the torque in accordance with the lengths of SST and the torque wrench. Click here
INSTALL INJECTION PIPE CLAMP
1. Install the new O-ring to oil level dipstick guide.
  
  Note
  
  Apply a light amount of clean engine oil to new O-ring.
2. Temporarily install the 2 pipe clamps and oil level dipstick guide to intake manifold.
3. Install the 2 injection pipe clamps with the 2 nuts. Tighten the 2 nuts until the clamps' edges make contact with the engine side clamps' edges.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install a new cylinder head cover gasket onto the cylinder head cover.
2. Install the cylinder head cover and the 2 cushions with the 2 bolts.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
3. Install the cylinder head cover cushion rubber.
4. Install the wire harness and connect the 5 connectors.
5. Connect the ventilation hose.
INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the No. 2 cylinder head cover sub-assembly with a new gasket and the 2 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install the oil filler cap sub-assembly.
INSTALL VENTURI ASSEMBLY
1. Remove any seal packing material from the contact surface.
2. Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  - Remove any oil from the contact surface.
  - Apply seal packing to the inner side of the bolt holes.
  - Install the intake pipe with EGR valve within 3 minutes of applying the seal packing.
  - Do not run the engine for at least 2 hours after installing.
3. Install the intake pipe with EGR valve with the 4 bolts.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
INSTALL EGR VALVE BRACKET
1. Install the EGR valve bracket with 4 bolts.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
INSTALL EGR COOLER SUB-ASSEMBLY
1. Install the EGR cooler with a new gasket and the 2 bolts.
  
  Torque:
  
  Flange
  
  55 N*m { 560 kgf*cm, 41 ft.*lbf }
  
  Engine
  
  69 N*m { 700 kgf*cm, 51 ft.*lbf }
2. Connect the water by-pass hose.
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install 4 new gaskets and water by-pass pipe sub-assembly with the 2 union bolts and 3 bolts.
  
  Torque:
  
  for Union Bolt
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
  
  for Bolt
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
2. Connect the 2 hoses to the EGR valve.
INSTALL WIRE HARNESS AND CONNECTORS
1. Connect the 3 connectors.
INSTALL DIESEL THROTTLE BODY
1. Remove any seal packing material from the contact surface.
2. Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.
  Tech Tips
  
  Remove any oil from the contact surface.
  
  Apply seal packing to the inner side of the bolt holes.
  
  Install the diesel throttle body assembly within 3 minutes of applying the seal packing.
  
  Do not run the engine for at least 2 hours after installing.
3. Install the diesel throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
4. Connect the 2 diesel throttle body connectors.
INSTALL INTAKE AIR PIPE NO. 1 WITH AIR HOSE NO. 4
1. Install the No. 1 intake air pipe with No. 4 air hose with the hose band.
2. Install the bolt, and connect the intake air temperature sensor connector.
  
  Torque:
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
3. Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.
  
  Torque:
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
4. Install the bracket with the 2 bolts.
  
  Torque:
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
5. Install the hose band.
INSTALL VENTILATION PIPE SUB-ASSEMBLY
INSTALL NO. 2 INTAKE PIPE
1. Install the No. 2 intake pipe with the 3 bolts and 2 bands.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
ADD ENGINE COOLANT
1. Add engine coolant.
  
  Specified capacity
  
  14.7 liters (15.5 US qts, 12.9 Imp. qts)
  Tech Tips
  - TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
  - Contact your TOYOTA dealer for further details.
2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.
3. Install the radiator cap.
4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
5. Bleed air from the cooling system.
  1. Warm up the engine until the thermostat opens.
    
    While the thermostat is open, circulate the coolant for several minutes.
  2. Press the inlet and outlet radiator hoses several times by hand to bleed air.
    Note
    - Be careful as the radiator hoses are hot.
    - Keep your hands away from the radiator fan.
6. Stop the engine and wait until the coolant cools down.
7. Remove the radiator cap and check the coolant level.
8. If the coolant level has dropped, add coolant.
9. Check the coolant level inside the radiator reservoir tank again. If it is below the full level, add coolant.
BLEED AIR FROM FUEL SYSTEM

Tech Tips

Click here.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
REGISTER INJECTOR COMPENSATION CODE
1. Register the injector compensation code Click here.
INSPECT FOR INJECTOR COMPENSATION CODE

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

Specified capacity
14.7 liters (15.5 US qts, 12.9 Imp. qts)

INSPECT FOR FUEL LEAK

Perform the Active Test.

Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

Note

Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.
Connect the intelligent tester to the DLC3.
Start the engine.
Turn the intelligent tester on.
Select the following menu items: Powertrain / Engine / Active Test.

Perform the Active Test.

Tester Display	Test Part	Control Range	Diagnostic Notes
Test the Fuel Leak	Pressurizing common rail internal fuel pressure, and checking for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected Above conditions preserved while test is ON

INSPECT FOR COOLANT LEAK
1. Remove the radiator cap.
  
  CAUTION:
  
  Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
2. Fill the radiator with coolant and attach a radiator cap tester.
3. Warm up the engine.
4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm², 19.9 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
5. Install the radiator cap.
INSPECT FOR OIL LEAK