FUEL INJECTOR INSTALLATION


  1. REMOVE INJECTION NOZZLE SEAT GASKET


    1. Install 4 new injection nozzle seat gaskets to the cylinder head.

  2. INSTALL INJECTOR ASSEMBLY

    Note

    A01CJFWE04
    Text in Illustration
    *1 Injector Compensation Code

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

    2. A01CI6EE02
      Text in Illustration
      *1 O-ring

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

    3. Install a new gasket to each injector.

    4. Referring to each cylinder number identification tag attached to the fuel injector assemblies, insert the fuel injector assembly, nozzle holder clamp, and nozzle holder clamp bolt for each cylinder.

      Note


      • Check that the tip of the fuel injector has no foreign matter attached.

      • When reusing the fuel injectors, reinstall them to the same cylinder they were removed from. 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.

    5. A01CGOO

      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.

    6. A01CIVM

      Install 4 new holder seals.

      Note

      Securely insert the tip of each holder seal into each fuel injector.

    7. A01CIAR

      Temporarily install the nozzle leakage pipe assembly and 5 new gaskets with the 5 hollow screws.

      Note

      Make sure that the hollow screws and nozzle leakage pipe assembly are not deformed or damaged.

    8. A01CHN3

      Temporarily tighten the union nuts of the injection pipes No. 1, No. 2, No. 3 and No. 4 by hand.

      Note

      If an injector has been replaced, the corresponding injection pipe must also be replaced.

    9. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      25 N*m  { 255 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.

    10. Tighten the 5 hollow screws.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

      Note

      If the nozzle leakage pipe assembly has been tightened to more than the specified torque, replace it with a new one.

    11. A01CHN3

      Using a union nut wrench (17 mm), tighten the 8 union nuts.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

      Note

      Refer to the torque above when not using the union nut wrench. When using the union nut wrench, calculate the torque in accordance with the lengths of the union nut wrench and torque wrench Click here.

  3. INSTALL INJECTION PIPE CLAMP


    1. Install a new O-ring to the oil level gauge guide.

      Note

      Apply a small amount of clean engine oil to the new O-ring.

    2. A01CGTY

      Temporarily install the 2 pipe clamps and oil level gauge guide to the intake manifold.

    3. Install the 2 injection pipe clamps with the 2 nuts. Tighten the 2 nuts until the clamp edges make contact with the engine side clamp edges.

    4. Install the oil level gauge.

  4. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  6. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly.

  7. INSTALL VENTURI ASSEMBLY


    1. A01CI8SE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.

      • Install the venturi within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the venturi assembly with the 4 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    3. Install the bracket with the bolt.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  8. INSTALL DIESEL THROTTLE BODY


    1. Remove any seal packing material from the contact surface.

    2. A01CJAVE02
      Text in Illustration
      *1 70 mm (2.75 in.)
      *2 Seal Packing

      Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.0591 to 0.0984 in. )) as shown in the illustration.

      Tech Tips


      • Remove any oil from the contact surface.

      • 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. A01CH93

      Install the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CHFJ

      Connect the 2 diesel throttle body connectors.

  9. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJB2E01
      Text in Illustration
      *1 Bolt
      *2 Union Bolt

      Install 4 new gaskets and the water by-pass pipe sub-assembly with the 2 union bolts and 3 bolts.

      Torque:
      for Union Bolt
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for Bolt
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    2. Connect the 3 wire harness clamps.

    3. Connect the 2 hoses to the EGR valve.

  10. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  11. INSTALL WIRE HARNESS AND CONNECTORS


    1. Connect the 3 connectors and 4 wire harness clamps and then install the bolt.

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

  12. INSTALL EGR COOLER SUB-ASSEMBLY


    1. Install the EGR cooler, bracket and 2 new gaskets with the 6 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.

  13. INSTALL NO. 4 AIR HOSE


    1. A01CJ8A

      Install the No. 4 air hose with 2 new clamps.

  14. INSTALL NO. 1 AIR HOSE


    1. A01CJCPE02
      Text in Illustration
      *a Upper Side

      Install the No. 1 air hose with the 2 bolts and a new hose clamp as shown in the illustration.

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

  15. INSTALL NO. 2 INTAKE PIPE


    1. Install the No. 2 intake pipe and No. 1 air hose with the 3 bolts and 2 new hose bands.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  16. ADD ENGINE COOLANT


    1. Add engine coolant.

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

      Note

      Never use water as a substitute for engine coolant.

      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 is 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 sub-assembly.

    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 sub-assembly 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.

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  18. REGISTER INJECTOR COMPENSATION CODE


    1. Register the injector compensation code Click here.

  19. INSPECT FOR INJECTOR COMPENSATION CODE

  20. BLEED AIR FROM FUEL SYSTEM

    Tech Tips

    Click here.

  21. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop or Start

        • Fuel pressure inside common rail is pressurized to specified value and engine speed is increased to 2000 rpm when Start is selected.

        • Above conditions preserved while Start is selected.

  22. INSPECT FOR COOLANT LEAK


    1. Remove the radiator cap sub-assembly.

      CAUTION:

      Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. A01CIGLE02
      Text in Illustration
      *1 Radiator Cap Tester

      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 sub-assembly.

  23. INSPECT FOR OIL LEAK