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, clean them with a brush and compressed air.

INSTALL INJECTOR ASSEMBLY
Note

Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.
1. 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. Install one of the O-rings 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 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. Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.
  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 clamp is set properly.
  
  To tighten the clamp bolts, first tighten them by hand until they cannot be turned further. The bolts will be tightened to the specified torque in a following step.
  
  When tightening the bolts, be careful 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.
  Tech Tips
  
  Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.
7. Temporarily install the 4 injection pipes with the union nuts.
  
  Tech Tips
  
  Loosely tighten the union nut so that the injector can be positioned.
8. 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.
9. Set the nozzle leakage pipe and 5 new gaskets in place.
10. Apply a small amount of oil to the 4 injector hollow screws and union bolt.
11. Temporarily install the nozzle leakage pipe with the 4 injector hollow screws and union bolt.
12. Tighten the 4 holder clamp bolts.
  
  Torque:
  
  22 N*m { 220 kgf*cm, 16 ft.*lbf }
13. Remove the 4 injection pipes.
14. 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.

INSPECT FOR FUEL LEAK

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

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

SST: 09280-00010

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

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

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, maintain 100 kPa (1.0 kgf/cm², 15 psi) of pressure for 60 seconds and check that no bubbles form.

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
1. Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover 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.
3. Remove any old seal packing (FIPG material) from the cylinder head.
4. Apply seal packing to the 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 head cover within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after installing the cylinder head cover.
5. Temporarily install the cylinder head cover 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.
INSTALL NO. 1 CYLINDER HEAD COVER SILENCER
1. Install the No. 1 cylinder head cover silencer to the cylinder head cover.
INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
INSTALL COMMON RAIL ASSEMBLY
1. Install the common rail with the 2 bolts.
  
  Torque:
  
  38 N*m { 387 kgf*cm, 28 ft.*lbf }
INSTALL 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 4 injection pipes with the union nuts.
2. Install the 3 No. 2 injection pipe clamps with the 3 bolts.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. 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.
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 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.
CONNECT ENGINE WIRE
1. Attach the 5 clamps.
2. Connect the 5 connectors.
3. Connect the ECM connector Click here.
4. Attach the clamp.
5. Install the bolt.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
6. Install the generator wire to terminal B with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
7. Install the terminal cap.
8. Install the engine wire with the bolt.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
9. Connect the 4 connectors and attach the 3 clamps.
10. Connect the engine wire with the 7 bolts.
  
  Torque:
  
  for bolt A
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  for bolt B
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
11. Connect the 7 connectors.
12. Attach the clamp and connect the engine wire to the No. 1 timing belt cover.
13. Connect the glow plug connector and attach the clamp.
14. Attach the 3 clamps and connect the water by-pass hose and oil return hose.
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
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 union bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for bolt A
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 3 FUEL PIPE
1. Apply a light coat of fuel to the O-ring of the fuel check valve.
2. Temporarily install the No. 3 fuel pipe with the 3 bolts.
3. Temporarily install a new gasket and the fuel check valve.
4. Temporarily install 2 new gaskets and the 2 union bolts.
5. for Engine Rear Side:
  
  Tighten the 2 bolts and union bolt.
  
  Torque:
  
  for union bolt
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  for bolt
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
6. for Engine LH Side:
  1. Tighten the fuel check valve and bolt.
    
    Torque:
    
    for fuel check valve
    
    32 N*m { 321 kgf*cm, 23 ft.*lbf }
    
    for bolt
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  2. Using a 6 mm hexagon wrench, tighten the union bolt.
    
    Torque:
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
    
    Note
    
    Place the part of the gasket labeled A against the No. 3 fuel pipe as shown in the illustration and tighten the union bolt.
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 }
INSTALL NO. 3 NOZZLE LEAKAGE PIPE
1. Apply a light coat of fuel to the O-ring of the fuel check valve.
2. Temporarily install the No. 3 nozzle leakage pipe with the bolt.
3. Temporarily install a new gasket and the fuel check valve.
4. Tighten the fuel check valve and bolt.
  
  Torque:
  
  for fuel check valve
  
  32 N*m { 321 kgf*cm, 23 ft.*lbf }
  
  for bolt
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
5. Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
6. Connect the 3 fuel hoses.
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.
2. Tighten the compressor and magnetic clutch with the 4 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
1. Remove the attached vinyl tape from the hose.
2. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and magnetic clutch.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring onto the cooler refrigerant suction hose.
4. Install the cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the attached vinyl tape from the hose.
2. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and magnetic clutch.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring onto the cooler refrigerant discharge hose.
4. Install the cooler refrigerant discharge hose onto the compressor and magnetic clutch with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
INSTALL FAN AND GENERATOR V BELT
1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.
  
  Note
  
  Make sure that the fan and generator V belt is set properly on each pulley.
2. Check that the indicator mark of the V-ribbed belt tensioner Click here.
INSTALL COMPRESSOR OUTLET ELBOW
1. Install the compressor outlet elbow with the 2 hose clamps and bolt.
  
  Torque:
  
  for bolt
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  for hose clamp A
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
  
  for hose clamp B
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
INSTALL EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM REGISTRATION
1. Perform registration of the injector compensation codes Click here.
BLEED AIR FROM FUEL SYSTEM
1. Using the hand pump mounted on the fuel filter cap, bleed 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 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 GTS to the DLC3.
5. Turn the ignition switch to ON and turn the GTS on.
6. Clear the DTCs.
  - w/ DPF: Click here
  - w/o DPF: Click here
7. Start the engine.*1
8. 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.
  
  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.
  - w/ DPF: Click here
  - w/o DPF: 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.

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

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

OK
No DTCs are output.

ADD ENGINE COOLANT

Firmly tighten the drain plugs.

Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

Standard Capacity

Item	Specified Condition
w/o Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)
w/ Front Heater	14.2 liters (15.0 US qts, 12.5 Imp. qts)
w/ Front and Rear Heaters	16.2 liters (17.1 US qts, 14.3 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).

Loosen the bleeder plug of the outlet housing.
When air is bled and the engine coolant drains out, firmly tighten the bleeder plug.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Add engine coolant up to the B line mark in the radiator reservoir assembly and install the radiator reservoir cap sub-assembly.
Warm up the engine until the thermostat opens.
1. While the thermostat is open, circulate the engine coolant for several minutes.
  
  Tech Tips
  
  The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
After the engine cools down, check that the engine coolant level is between the LOW and FULL level marks.

CHARGE REFRIGERANT

Perform vacuum purging using a vacuum pump.

Charge with refrigerant HFC-134a (R134a).

Standard
Single A/C
520 to 580g (18.3 to 20.5 oz.)
Dual A/C
670 to 730g (23.0 to 25.7 oz.)

SST: 07110-58060 ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

Note

Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.
Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

Tech Tips

Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

WARM UP ENGINE
1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.
  
  Note
  
  Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
PERFORM REGISTRATION
1. Perform pilot quantity learning Click here.
INSPECT FOR LEAKAGE OF REFRIGERANT
1. After recharging refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.
2. Carry out the test under the following conditions:
  - Stop the engine.
  - Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
  - Repeat the test 2 or 3 times.
  - Make sure that there is some refrigerant remaining in the refrigeration system.
    
    When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
3. Using a gas leak detector, check for leakage of the refrigerant line.
4. Bring the gas leak detector close to the drain hose with the detector's power off.
  Tech Tips
  
  After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.
  
  Bring the gas leak detector sensor under the drain hose.
  
  When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.
  
  If such reaction is unavoidable, the vehicle must be lifted up.
5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.
6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.
INSPECT FOR COOLANT LEAK

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Hot, pressurized engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.
2. Warm up the engine.
3. 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.
  
  Tech Tips
  
  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.

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test.

Perform the Active Test.

Tester Display	Test Part	Control Range	Diagnostic Notes
Test the Fuel Leak	Pressurize common rail interior and check for fuel leaks	Stop/Start	Fuel pressure inside common rail increased to specified value and engine speed increased to 2000 rpm when Active Test is performed Above conditions preserved while Active Test is being performed

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 for 5 minutes.
2. Check that the oil level is between the upper level and lower level of the engine oil level dipstick. If the oil level is low, check for leakage and add oil up to the upper level of the engine oil level dipstick.
  
  Note
  
  Do not fill engine oil above the full level mark.