FUEL INJECTOR (w/ DPF) 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.


  1. INSTALL FUEL INJECTOR

    Note

    Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.


    1. A01KGMP

      Install 4 new injection nozzle seats to the cylinder head.

    2. A01KH3LE03
      Text in Illustration
      *1 O-Ring

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

    3. Install one of the O-rings to each injector as shown in the illustration.

    4. Install the 4 injectors into the cylinder head.

      Note


      • Install 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 being fully seated. If so, pull out the injector and reinstall it.

      • Always reinstall 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. A01KIR7

      Temporarily install the 4 injection pipes with the union nuts.

      Note

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

      Tech Tips

      To position the injectors, loosely tighten the union nuts.

    7. A01KGXQ

      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.

    8. A01KGUME06
      Text in Illustration
      *1 Union Bolt
      *2 Gasket
      *3 Hollow Screws

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

    9. Apply a small amount of clean engine oil to the 4 injector hollow screws and union bolt.

    10. Temporarily install the nozzle leakage pipe with the 4 injector hollow screws and union bolt.

    11. A01KHB7E03

      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


      • A01KIJGE06

      • 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 clean engine oil to the threads and under the heads of the clamp bolts.

    12. Tighten the 4 No. 1 nozzle holder clamp bolts.

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

    13. Loosen the union nuts and remove the 4 injector pipes.

    14. A01KHBVE07
      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.

    15. 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.

  2. INSPECT FOR FUEL LEAK


    1. A01KGJTE02

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


      1. Install a new gasket and the No. 2 nozzle leakage pipe to the cylinder head with SST.

        SST
        09280-00010
        Part No.
        23762-27010 (No. 2 nozzle leakage pipe)
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }
        Text in Illustration
        *1 No. 2 Nozzle Leakage Pipe
        *2 Gasket

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

      3. A01KHBVJ02

        Install SST (turbocharger pressure gauge) to the fuel return side of the nozzle leakage pipe, maintain 250 kPa (2.5 kgf/cm2, 36 psi) of pressure for 60 seconds and check that no bubbles form.

        SST
        09992-00242

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

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

        Note

        Never reinstall the disassembled union bolt to the engine.

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01KG75E04
      Text in Illustration
      *a Upper Side of Cylinder Head Cover Sub-assembly

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover sub-assembly as shown in the illustration.

      Note


      • Do not install the gaskets at an angle.

      • Keep the lip of the gasket free from foreign materials.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

    3. Remove any old seal packing from the cylinder head.

    4. A01KF06E08

      Apply seal packing to the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      A01KI6A Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover.

    5. A01KF9IE02

      Temporarily install the cylinder head cover sub-assembly with the 10 bolts and 2 nuts in the order shown in the illustration. Then, tighten the 10 bolts and 2 nuts in the order shown in the illustration in 2 progressive steps.

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

    6. Connect the ventilation hose.

    7. Install 4 new nozzle holder seals.

  4. INSTALL NO. 1 CYLINDER HEAD COVER SILENCER


    1. Install the No. 1 cylinder head cover silencer.

  5. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  6. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator to the intake manifold.

  7. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Note


    • When replacing the common rail, cylinder head sub-assembly, it is necessary to replace the No. 1 to No. 4 injection pipe sub-assembly with a new one.

    • Before installing the injection pipes and common rail assembly, clean them with a brush and compressed air.


    1. Temporarily install the No. 1 to No. 4 injection pipes.

    2. Install the 3 No. 2 injection pipe clamps to the No. 1 to No. 4 injection pipes with the 3 bolts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    3. Using a 17 mm union nut wrench, install the No. 1 to No. 4 injection pipes.

      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.

  8. CONNECT ENGINE WIRE


    1. Engage the 4 wire harness clamps.

      A01KG4TE01

    2. Install the 4 bolts.

      Torque:
      Bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Bolt B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt C
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    3. Connect the 10 connectors.

    4. Connect the glow plug connector and engage the wire harness clamp.

  9. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Temporarily install a new gasket and the No. 2 nozzle leakage pipe assembly with the union bolt and 3 bolts.

    2. A01KIIVE01

      Tighten the union bolt and 3 bolts.

      Torque:
      Union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Text in Illustration
      A01KGZT Union Bolt

  10. INSTALL NO. 3 FUEL PIPE


    1. A01KGWWE03
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. Temporarily install 3 new gaskets and the No. 3 fuel pipe with the fuel check valve, 2 union bolts and 3 bolts.

      A01KHGRE02
      Text in Illustration
      *1 Gasket - -
      A01KGZT Union Bolt A01KF96 Fuel Check Valve
      A01KFFI Bolt - -

    3. Tighten the 2 bolts and fuel check valve.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    4. Using a socket hexagon wrench, tighten the 2 union bolts and bolt.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Union bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

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

  12. INSTALL NO. 3 NOZZLE LEAKAGE PIPE


    1. A01KIBLE03
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. Temporarily install a new gasket and the No. 3 nozzle leakage pipe with the fuel check valve and bolt.

    3. Tighten the fuel check valve and bolt.

      Torque:
      Fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }
      Bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    4. Install the No. 2 injection pipe clamp with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    5. Connect the 3 fuel hoses.

  13. INSTALL EGR VALVE ASSEMBLY

    Click here

  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  15. PERFORM REGISTRATION


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

  16. BLEED FUEL LINE


    1. A01KETN

      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. A01KI71E05
      Text in Illustration
      *a

      Reference

      (Active Test Operation)

      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.

      A01KH8CE14
      Text in Illustration
      *a Active Test Operation *b ON
      *c OFF *d time
      *e 1st time *f 2nd time
      *g 5th time *h 10 seconds
      *i 3 minutes - -

      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.

  17. ADD ENGINE COOLANT


    1. Pour coolant into the radiator until it overflows.

      Capacity
      Specification Capacity
      w/o Heater 9.8 liters (10.3 US qts, 8.6 Imp. qts)
      w/ Front Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Front and Rear Heater 11.5 liters (12.2 US qts, 10.1 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    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 securely.

    4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

    5. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    6. Maintain the engine speed at 2000 to 2500 rpm.

    7. Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.

      CAUTION:


        When squeezing the radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

    8. Stop the engine and wait until the coolant cools down.

    9. Remove the radiator cap and check the coolant level inside the radiator.

    10. If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.

    11. Check the coolant level inside the radiator reservoir tank again.

      If it is below the full level, add coolant.

  18. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

    2. A01KH30E02
      Text in Illustration
      *1 Radiator Cap Tester

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and head.

    5. Reinstall the radiator cap.

  19. BLEED FUEL LINE


    1. A01KETN

      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. A01KI71E05
      Text in Illustration
      *a

      Reference

      (Active Test Operation)

      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.

      A01KH8CE14
      Text in Illustration
      *a Active Test Operation *b ON
      *c OFF *d time
      *e 1st time *f 2nd time
      *g 5th time *h 10 seconds
      *i 3 minutes - -

      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.

  20. PERFORM REGISTRATION


    1. Perform pilot quantity learning Click here.

  21. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      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 Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurize the common rail interior and check for fuel leaks Stop/Start

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

        • Above conditions preserved while test is ON

          Tech Tips

          If this Active Test is performed when the engine is cold, combustion may become unstable. However, this is not a malfunction. It is only necessary to confirm that the pressure rises to the target pressure and that there are no fuel leaks.

  22. INSPECT FOR OIL LEAK

  23. INSPECT FOR EXHAUST GAS LEAK