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ТОПЛИВНАЯ ФОРСУНКА УСТАНОВКА

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  1. Click here

    INSTALL INJECTOR ASSEMBLY

    Note:

    It is necessary to register the injector compensation code manually in the ECM using the intelligent tester, as each injector assembly has a different injection characteristic.


    1. A01BBVS

      Put tags with cylinder numbers (#1 to #4) onto the new injector assembly in order to make sure of the right combinations with the right cylinders.

      Standard Resistance
      0.85 to 1.05 Ω at 20°C (69°F)

    2. Register the injector compensation code manually (Click here).

    3. A01BBRP

      Install a new injection nozzle sheet to the cylinder head.

    4. A01BA5VE01

      Install a new O-ring.

      Tip:

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

    5. Install the injector assembly to 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:

      In case of having replaced the injector, replace the injection pipe, too.

      Tip:

      Tighten the union nuts of the injection pipes by hand until them cannot turn.

    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 tighten the 4 hollow screws, union bolt by hand until them cannot turn.

      Note:

      Confirm the deformation and damage the injector hollow screws, and union bolt.

    9. A01BGA2

      Install the 4 nozzle holder clamps and 4 new washers with the 4 bolts as show in the illustration.

    10. Tighten the new washers and 4 bolts.

      22 N*m 220 kgf*cm 16 ft.*lbf
      Note:

      • Pay attention the direction of washers.

      • 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 bearing surface of the bolt touches the washer, then tighten them by the specified torque.

    11. A01BE25E01

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

      16 N*m 163 kgf*cm 12 ft.*lbf

    12. Tighten the union bolt.

      13 N*m 130 kgf*cm 9 ft.*lbf
      Note:

      In case of overtightening the nozzle leakage, replace it with a new one.

    13. Remove the injection pipe No.1, No.2, No.3 and No.4.

  2. Click here

    CHECK NOZZLE LEAKAGE PIPE LEAK


    1. A01BH7N

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

      09280-00010
      21 N*m 215 kgf*cm 15 ft.*lbf
      Nozzle leakage pipe No.2 23762 - 27010
      Gasket 90904 - 30012

    2. Using SST (turbo charge pressure gauge), set the SST to the leakage pipe No.2 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:

      Be sure to keep specified pressure, preventing form leakage.

      Tip:

      • Apply a coat of engine oil to the nozzle leakage pipe assembly connection, and check that no bubbles come 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 the SST, nozzle leakage pipe assembly No.2.

  3. Click here

    INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. A01BCQO

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

    2. A01BEHR

      Install the check valve nozzle leakage pipe assembly No.2 and a new gasket.

      21 N*m 214 kgf*cm 15 ft.*lbf
    3. A01BE3H

      Tighten the 2 bolts.

      13 N*m 133 kgf*cm 10 ft.*lbf
    4. A01BE3U

      Install the 3 fuel hoses on the nozzle leakage pipe assembly No.2.

  4. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BE87E02

      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 old seal packing (FIPG) from the cylinder head.

    4. A01BHVSE01

      Apply a seal packing to the specific places described in the illustration.

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

      • After applying the seal packing, parts must be assembled within 3 minutes, and then tighten within 15 minutes.

      • Otherwise the material must be removed and reapplied.

      • Do not start the engine 2 hour after the installation.

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

      9.0 N*m 92 kgf*cm 80 in.*lbf

    6. Connect the ventilation hose.

    7. Install a new nozzle holder seal.

  5. Click here

    INSTALL INJECTION PIPE

    09023-12701
    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 clean the joint of the injection pipe.


    1. Install the injection pipes.


      1. A01BFG2

        Temporarily install the 4 injection pipes.

      2. A01BC89

        Install the injection pipe clamp No.3 in 2 nuts.

        5.0 N*m 51 kgf*cm 44 in.*lbf
      3. A01BFG2E01

        Fasten the union sequentially, from the injection pipe common rail to the injector, using SST.

        09023-12701
        Use union nut wrench and torque wrench
        32 N*m 326 kgf*cm 24 ft.*lbf
  6. Click here

    INSTALL OIL LEVEL GAGE GUIDE


    1. Установите на трубку щупа проверки уровня масла новое уплотнительное кольцо.

    2. Нанесите на уплотнительное кольцо тонкий слой моторного масла.

    3. Установите трубку щупа проверки уровня масла и закрепите ее болтом.

      8,0 Н*м 82 кгс*см 71 фунт-сила-дюйм

    4. Установите щуп проверки уровня масла.

  7. Click here

    INSTALL INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BEP8E01

      Temporarily install 2 new gaskets and intake air connector No.2 to the intake air connector.

    2. A01BDK1

      Temporarily tighten the intake air connector assembly with the bolt and 2 nuts.

    3. Tighten the manifold stay with the bolt.

    4. Tighten the intake air connector with the bolt and 2 nuts.

    5. Install the vacuum hose to the intake air connector.

  8. Click here

    TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Temporarily tighten the EGR valve assembly with the sensor.


      1. A01BACYE01

        Install 2 new gaskets and the EGR valve to the intake air connector as shown in the illustration.

      2. A01BH7Q

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

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

      4. Temporarily tighten the manifold stay with the bolt.

      5. A01BAPE

        Connect the EGR valve position sensor connector.

      6. Connect the intake air temperature sensor connector.

    2. Install the vacuum regulating valve.


      1. A01BHSL

        Install the vacuum regulating valve with the 2 bolts.

        20 N*m 204 kgf*cm 15 ft.*lbf

      2. Connect the 2 vacuum hoses and the regulating valve connector.

  9. Click here

    INSTALL EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BG49

      Install the 2 gaskets to the cylinder head and EGR pipe sub-assembly as shown in the illustration.

    2. A01BD88

      Install the EGR pipe sub-assembly with the 2 bolts and 2 nuts.

      13 N*m 133 kgf*cm 10 ft.*lbf

    3. Tighten the intake air connector with the bolt and the 2 nuts.

      20 N*m 204 kgf*cm 15 ft.*lbf

    4. Tighten the manifold stay.

      19 N*m 194 kgf*cm 14 ft.*lbf
  10. Click here

    REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. Remove the 3 bolts, the 2 nuts, and the EGR pipe sub-assembly.

    2. Remove the 2 gaskets.

  11. Click here

    INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note:

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


    1. Install a new gasket to intake air connector.

    2. A01BBJH

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

      20 N*m 204 kgf*cm 15 ft.*lbf
    3. A01BCMO

      Connect the 2 throttle body connectors.

  12. Click here

    INSTALL AIR HOSE NO.4


    1. A01BGX6

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

      6.0 N*m 61 kgf*cm 53 in.*lbf
  13. Click here

    INSTALL EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BG49

      Install 2 new gaskets to the cylinder head and the EGR pipe sub-assembly No.1 as shown in the illustration.

    2. A01BD88

      Install the EGR pipe with the 2 bolts and the 2 nuts.

      13 N*m 133 kgf*cm 10 ft.*lbf
    3. A01BGWP

      Connect the fuel pressure sensor connector.

  14. Click here

    CONNECT OIL RETURN HOSE


    1. A01BFPG

      Connect the oil return hose with the clip.

  15. Click here

    INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBMI

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

      8.0 N*m 82 kgf*cm 71 in.*lbf
  16. Click here

    INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Установите вспомогательную крышку технологического отверстия двигателя и закрепите ее 5 болтами.

      13 Н*м 133 кгс*см 10 фунт-сила-футов
  17. Click here

    INSTALL FRONT DOOR SCUFF PLATE RH

  18. Click here

    INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Выполните те же действия, что были описаны выше для противоположной стороны (см. стр.Click here).

  19. Click here

    INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Выполните те же действия, что были описаны выше для противоположной стороны (см. стр.Click here).

  20. Click here

    CHECK 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).

  21. Click here

    ADD ENGINE COOLANT


    1. Надежно затяните сливные пробки.

    2. Залейте охлаждающую жидкость в расширительный бачок системы охлаждения до верха горловины.

      Номинальный объем
      Параметр / Устройство Заданные условия
      Для моделей без подогревателя 13,6 литра (14,4 кварты США, 12,0 английской кварты)
      Для моделей с передним подогревателем 14,6 литра (15,4 кварты США, 12,8 английской кварты)
      Для моделей с передним и задним подогревателями 16,6 литра (17,5 кварты США, 14,6 английской кварты)
      Note:

      Не доливайте простую воду вместо охлаждающей жидкости двигателя.

      Tip:

      • Использование неподходящей охлаждающей жидкости может привести к повреждению системы охлаждения двигателя.

      • Разрешается использовать только охлаждающую жидкость "TOYOTA Super Long Life Coolant" или аналогичную высококачественную охлаждающую жидкость на основе этиленгликоля (а не на силикатной, аминовой, нитритной или борнокислой основе), изготовленную по гибридной технологии органических кислот с длительным сроком годности (охлаждающая жидкость, изготовленная по гибридной технологии органических кислот, состоит из низкофосфатных соединений и органических кислот).

    3. Ослабьте прокачной штуцер корпуса отводящего патрубка.

    4. После удаления воздуха и слива охлаждающей жидкости надежно затяните прокачной штуцер.

      8,0 Н*м 82 кгс*см 71 фунт-сила-дюйм
    5. A01BGFB

      Долейте охлаждающую жидкость в расширительный бачок радиатора до отметки B и установите пробку радиатора.

    6. Прогревайте двигатель, пока не откроется термостат.


      1. Когда термостат откроется, несколько минут прокачивайте охлаждающую жидкость.

        Tip:

        Время открывания термостата можно проверить, сжав входной патрубок радиатора рукой и убедившись, что охлаждающая жидкость поступает в шланг.

    7. A01BBOM

      После охлаждения двигателя убедитесь, что уровень охлаждающей жидкости находится между отметками "LOW" и "FULL".

  22. Click here

    CHECK FOR ENGINE COOLANT LEAKAGE


    1. Снимите пробку радиатора.

      CAUTION:

      Не снимайте пробку радиатора, пока двигатель и радиатор не остынут. Выброс горячей охлаждающей жидкости и пара под давлением может стать причиной серьезных ожогов.

    2. Убедитесь, что вокруг пробки и наливной горловины радиатора нет чрезмерных отложений ржавчины и окалины. Охлаждающая жидкость не должна содержать масло.

      Tip:

      При наличии избыточных загрязнений очистите каналы для охлаждающей жидкости и замените охлаждающую жидкость.

    3. Установите на место пробку радиатора.

  23. Click here

    BLEED FUEL LINE


    1. A01BEO7E01

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

  24. Click here

    INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover)

  25. Click here

    CONNECT BATTERY NEGATIVE CABLE

  26. Click here

    INSTALL BATTERY SERVICE HOLE COVER

  27. Click here

    CHECK FOR FUEL LEAKS


    1. PERFORM ACTIVE TEST


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch on.

      3. Turn the intelligent tester on.

      4. Enter the following menus: 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