FUEL INJECTOR (w/o DPF) INSTALLATION


  1. INSTALL INJECTOR ASSEMBLY

    A01BEN4E01

    Note

    When replacing the injector assembly with a new one, register the injector compensation code manually in the ECM using the intelligent tester, as each injector assembly has a different injection characteristic.


    1. A01BBVS

      While registering the injector compensation codes, put tags with cylinder numbers (#1 to #4) on the new injectors in order to match them into the correct cylinders.

    2. Register the injector compensation code manually Click here.

    3. A01BBRP

      Install a new injection nozzle seat onto the cylinder head.

    4. A01BA5VE02

      Install a new O-ring.

      Tech Tips

      Apply a light coat of engine oil to the O-ring.

    5. Install the injector assembly into each cylinder referring to the tags with cylinder numbers (#1 to #4).

      Note

      If the wrong injector assembly is installed on the cylinder, rough idling or noise may occur.

    6. Temporarily install the 4 injection pipes.

      Note

      When replacing the injector, replace the injection pipe as well.

      Tech Tips

      Hand tighten the union nuts of the injection pipes.

    7. A01BE7Q

      Apply a light coat of engine oil to the 4 hollow screws and union bolt.

    8. Temporarily install the nozzle leakage pipe assembly and 5 new nozzle leakage pipe gaskets and hand tighten the 4 hollow screws and union bolt until them cannot turn.

      Note

      Check the injector hollow screws and union bolt for any deformation or damage.

    9. A01BEKZ

      Install the 4 nozzle holder clamps and 4 new washers with the 4 bolts.

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

      Note


      • Do not install the washers in the wrong direction.

      • Clip the injector at the fork portion with a clamp which is set on the head of the cam cap bolt. At this time, check that the clamp does not hold the injector at the part where the spring is attached.

      • Temporarily torque the clamp bolts by hand until the bolt touches the washer, then tighten them by the specified torque.

    10. A01BE25E02

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

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

    11. Tighten the union bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      If the bolt is excessively tightened, replace the nozzle leakage pipe assembly with a new one.

    12. Remove injection pipe No. 1, No. 2, No. 3, and No. 4.

  2. INSPECT FOR NOZZLE LEAKAGE PIPE LEAK

    A01BCET

    1. Using SST, install the No. 2 nozzle leakage pipe and a new gasket.

      SST
      09280-00010
      Torque:
      21 N*m  { 215 kgf*cm, 15 ft.*lbf }
      No. 2 nozzle leakage pipe 23762 - 27010
      Gasket 90904 - 30012
    2. A01BGJ2

      Using SST (turbo charge pressure gauge), set the SST to the No. 2 nozzle leakage pipe and maintain 250 kPa (2.5 kgf/cm2, 37 psi) of pressure for 60 seconds to check that there are no leaks from the nozzle leakage pipe assembly.

      Note

      Maintain the pressure at the desired level to prevent fuel leakage.

      Tech Tips


      • Apply a coat of engine oil to the nozzle leakage pipe assembly connection, and check that no bubbles come out from the nozzle leakage pipe assembly.

      • Check that indication on the SST (turbo charger pressure gauge) does not go down while pressure is applied.

    3. Remove SST and the No. 2 nozzle leakage pipe assembly.

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BE87E03

      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. A01BHVSE02

      Apply a seal packing to the cylinder head as shown in the illustration.

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

      Note


      • Remove any old packing from the contact surface.

      • After applying the seal packing, install the cylinder head cover within 3 minutes, and tighten the bolts within 15 minutes.

    4. A01BF0S

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

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

    5. Connect the ventilation hose.

    6. Install new nozzle holder seals.

  4. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01BGX5E01

      Temporarily install the No. 2 nozzle leakage pipe assembly with the 3 bolts.

    2. Install the 2 union bolts and 2 new gaskets.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf, for bolt A }

    3. Tighten the 3 bolts.

      Torque:
      13 N*m  { 129 kgf*cm, 9 ft.*lbf, for bolt B }
    4. A01BBPS

      Connect the 4 fuel hoses to the No. 2 nozzle leakage pipe assembly.

  5. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01BDF3

    Note


    • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket, or timing gear case with a new one, replace the fuel inlet pipe.

    • Be careful not to adhere dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.


    1. Temporarily install the fuel inlet pipe.

    2. A01BC23

      Connect the No. 1 injection pipe clamp with the bolt.

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

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

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

    4. Using SST, tighten the union nut on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

      • This torque value is effective when SST is parallel to a torque wrench.

    5. Using SST, tighten the union nut on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

      • This torque value is effective when SST is parallel to a torque wrench.

  6. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Note


    • When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipes No. 1, No. 2, No. 3, and No. 4.

    • Keep the injection pipe connection clean.


    1. A01BF2K

      Install the injection pipes.


      1. Temporarily install the 4 injection pipes.

      2. A01BG01

        Install the 2 No. 2 injection pipe clamps with the 2 bolts.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. A01BC1D

        Using SST, tighten the union nut on the fuel injector side to the specified torque.

        SST
        09023-12701
        Torque:
        32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
        35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

        Tech Tips


        • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

        • This torque value is effective when SST is parallel to a torque wrench.

      4. A01BE78

        Using SST, tighten the union nut on the common rail side to the specified torque.

        SST
        09023-12701
        Torque:
        32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
        35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

        Tech Tips


        • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

        • This torque value is effective when SST is parallel to a torque wrench.

      5. A01BALH

        Install the 3 bolts.

      6. Connect the fuel injector connector and harness clamps.

  7. INSTALL OIL LEVEL GAUGE GUIDE


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

    2. Apply a light coat of engine oil to the O-ring.

    3. A01BF6Z

      Install the oil level gauge guide with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Install the oil level gauge.

  8. TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A01BACYE03

    1. Temporarily tighten the electric EGR control valve.


      1. Install 2 new gaskets and the electric EGR control valve onto the intake air connector as shown in the illustration.

      2. A01BH7Q

        Temporarily tighten the intake air connector with electric EGR control valve to the intake manifold with the bolt and the 2 nuts.

      3. Install the vacuum hose onto the intake air connector.

      4. Temporarily tighten the manifold stay with the bolt.

  9. TEMPORARILY TIGHTEN EGR COOLER ASSEMBLY

    A01BBGP

    1. Tighten the EGR cooler assembly stay bolt.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01BH3G

      Install the No. 2 water by-pass hose with the clip.

    3. Install the No. 4 water by-pass hose with the clip.

  10. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A01BEFZ

    1. Tighten the electric EGR control valve with the bolt and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01BBVC

      Connect the intake air temperature sensor connector.

    3. A01BG0F

      Connect the vacuum hose to the electric EGR control valve.

    4. Connect the electric EGR control valve connector.

    5. A01BH0B

      Install the vacuum regulating valve with bracket with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A01BDUS

      Connect the 2 vacuum hoses to the vacuum regulating valve.

    7. Connect the vacuum regulating valve connector.

  11. TIGHTEN EGR COOLER ASSEMBLY

    A01BBGP

    1. Tighten the EGR cooler assembly stay bolt.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01BH3G

      Install the No. 2 water by-pass hose with the clip.

    3. Install the No. 4 water by-pass hose with the clip.

  12. INSTALL MANIFOLD STAY


    1. Tighten the manifold stay bolt.

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

  13. INSTALL NO. 2 ENGINE SERVICE HOLE COVER


    1. A01BD0S

      Install the No. 2 engine service hole cover with the 3 bolts.

  14. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

    After removing and installing, or replacing the throttle body, be sure to perform the operation check.


    1. A01BBJH

      Install a new gasket onto the intake air connector.

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. A01BCMO

      Connect the 2 throttle body connectors.

  15. INSTALL NO. 4 AIR HOSE

    A01BGX6

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

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

  16. CONNECT OIL RETURN HOSE

    A01BCQX

    1. Connect the oil return hose with the 2 clips.

  17. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

    1. Install the vane pump oil reservoir assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  18. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover sub-assembly with the 5 bolts.

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

  19. INSTALL FRONT DOOR SCUFF PLATE RH

  20. INSTALL FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  22. INJECTOR COMPENSATION CODE


    1. Check that the injector compensation code registered in the injector assembly installed on each cylinder match the ones registered in the ECM. Click here

  23. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reserve tank assembly with coolant to the top of the inlet.

      Coolant capacity
      Condition Capacity
      w/ rear heater 18.2 liters (19.2 US qts, 16.0 lmp. qts)
      w/o rear heater 16.2 liters (17.0 US qts, 14.0 lmp. 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the coolant drains out, firmly install the bleeder plug.

    5. A01BGFB

      Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap.

    6. 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.

    7. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  24. INSPECT FOR ENGINE COOLANT LEAK

  25. BLEED FUEL LINE


    1. A01BEO7E01

      Using a hand pump, bleed air from the fuel system until pumping becomes difficult.

  26. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch ON.

      3. Turn the intelligent tester ON.

      4. Select the following menu items: Powertrain / ECD / 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/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

  27. INSPECT FOR OIL LEAK

  28. INSPECT FOR EXHAUST GAS LEAK

  29. PERFORM INITIALIZATION


    1. Perform initialization procedures Click here.

      Note

      Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.