FUEL INJECTOR (w/o 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.
  
  Tech Tips
  
  Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.
  Note
  
  The fork portion of the 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. Then, tighten the bolts 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.
7. Temporarily install the 4 injection pipes with the union nuts.
  
  Tech Tips
  
  To position the injectors, loosely tighten the union nut.
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. 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.
14. 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.
15. Remove the 4 injection pipes.

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).

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

SST: 09280-00010

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

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, 14.5 psi) of pressure for 60 seconds and check that no bubbles form.

SST

09992-00242

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. Install the cylinder head cover with the 10 bolts and 2 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
6. Install 4 new nozzle holder seals.
7. Connect the ventilation hose.
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 2 No. 2 injection pipe clamps with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 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.
5. Attach the 3 clamps and install the wire harness with the 4 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 }
6. Connect the 4 injector connectors.
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 bolt
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  
  for union bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Connect the 3 fuel hoses.
INSTALL VACUUM SWITCHING VALVE BRACKET
1. Install the vacuum switching valve bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Connect the 2 vacuum hoses and vacuum switching valve connector.
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
Note
- 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.
- Keep the fuel inlet pipe free of foreign matter.
1. Temporarily install the fuel inlet pipe with the union nuts.
2. Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
3. Install the No. 1 injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  
  Note
  
  If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.
4. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut 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.
5. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump 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.
INSTALL EGR COOLER ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM REGISTRATION
1. Perform registration of the injector compensation code 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 intelligent tester to the DLC3.
5. Turn the ignition switch to ON and turn the intelligent tester 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.
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.

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

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Turn the intelligent tester on.
Enter the following menus: Powertrain / ECD / Active Test.

Perform the Active Test.

Intelligent 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