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. Text in Illustration
  
  *1 New O-Ring
  
  Install an O-ring 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 fully seating. If so, pull out the injector and reinstall it.
  - Always return 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. Text in Illustration
  
  *1 Washer
  
  *a Downward
  
  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.
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.
9. Text in Illustration
  
  *1 Union Bolt
  
  *2 Hollow Screw
  
  Set the 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 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. Text in Illustration
  
  *1 Union Bolt
  
  Tighten the 4 hollow screws in order from 1 to 4.
  
  Torque:
  
  16 N*m { 163 kgf*cm, 12 ft.*lbf }
  
  Note
  
  If a 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.

Text in Illustration
*1	New O-Ring

Text in Illustration
*1	Washer
*a	Downward

Text in Illustration
*1	Union Bolt
*2	Hollow Screw

Text in Illustration
*1	Union Bolt

INSPECT FOR FUEL LEAK

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

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

SST

09992-00242
After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.
Remove SST, the No. 2 nozzle leakage pipe and gasket.

Note

Never reinstall the disassembled union bolt to the engine.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Text in Illustration
*1	No. 3 Cylinder Head Cover Gasket
*2	Cylinder Head Cover

Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

Note

Do not install the No. 3 cylinder head cover gaskets at an angle.
Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

Remove any old seal packing (FIPG material) from the cylinder head.
Text in Illustration

*1 Seal Packing

Apply seal packing to the specific 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 seal packing.
Install a new cylinder head cover gasket and the cylinder head cover with the 10 bolts and 2 nuts.

Torque:

9.0 N*m { 92 kgf*cm, 80 in.*lbf }
Install 4 new nozzle holder seals.

INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the No. 2 cylinder head cover with the 4 bolts.
  
  Torque:
  
  for bolt A
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
  
  for bolt B
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Attach the 2 wire harness clamps and connect the wire harness to the No. 2 cylinder head cover.
3. Connect the 4 injector connectors.
INSTALL VENTILATION PIPE
1. Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head cover to the cylinder head sub-assembly with the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
2. Type A
  
  Connect the No. 3 turbo water hose and No. 4 turbo water hose to the ventilation pipe, and slide the 2 clamps to secure the hose.
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
1. Text in Illustration
  
  *1 Union Bolt
  
  Temporarily install the No. 2 nozzle leakage pipe with the 4 bolts.
2. Temporarily install a new gasket and the union bolt.
3. Tighten the 4 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 OIL FILTER SUB-ASSEMBLY
1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.
4. Using SST, tighten the oil filter. Depending on the space available, choose from the following.
  
  SST
  
  09228-07501
  1. If enough space is available, use a torque wrench to tighten the oil filter.
    
    Torque:
    
    17 N*m { 173 kgf*cm, 13 ft.*lbf }
  2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 of a turn by hand or with a common wrench.
INSTALL NO. 4 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 No. 4 injection pipe with the union nuts.
2. Install the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  Note
  - If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
  - Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
  - When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.
3. Text in Illustration
  
  *a Common Rail Side
  
  *b Injector Side
  
  Using a 17 mm union nut wrench, tighten the injection 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.
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.

Text in Illustration
*1	Seal Packing

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

Text in Illustration
*1	Union Bolt

Text in Illustration
*a	Common Rail Side
*b	Injector Side

INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE

Text in Illustration
*A	w/o EGR System
*B	w/ EGR System
*1	White Mark
*2	Blue Mark

Install the manifold stay with vacuum switching valve with the 2 bolts and connect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

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

Note

Make sure the vacuum hose color matches the connection area color.

w/ EGR Cooler:

Connect the No. 3 vacuum transmitting hose.
Text in Illustration

*1 Yellow Mark

*2 Pink Mark

w/ EGR System:

Connect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.
Note
- Make sure the vacuum hose color matches the connection area color.
- Push on the hose until it reaches the bent part of the pipe.
Connect the No. 1 vacuum transmitting hose.
Connect the vacuum switching valve connector.
1. w/o EGR System:
  
  Connect the connector.
2. w/ EGR System without EGR Cooler:
  
  Connect the 2 connectors.
3. w/ EGR System with EGR Cooler:
  
  Connect the 3 connectors.

INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)
1. Set a new gasket on the intake manifold.
  
  Note
  
  Make sure the claw of the gasket face the intake manifold as shown in the illustration.
2. Install the intake air connector with diesel throttle body with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration.
3. Connect the throttle position sensor connector.
CONNECT ENGINE WIRE (w/o EGR System)
1. for LHD:
  
  Connect the engine wire with the clamp and install the 2 bolts.
  
  Torque:
  
  for bolt A
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  22 N*m { 220 kgf*cm, 16 ft.*lbf }
2. for RHD:
  
  Connect the engine wire with the bolt.
  
  Torque:
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
INSTALL AIR CONNECTOR STAY (w/o EGR System)
1. Temporarily install the air connector stay with the 3 bolts.
2. Tighten the bolt labeled A.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Tighten the 2 bolts labeled B.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR System)
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 No. 1, No. 2 and No. 3 injection pipes with the union nuts.
2. Text in Illustration
  
  *1 No. 2 Injection Pipe
  
  Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  
  Tech Tips
  
  If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.
3. Text in Illustration
  
  *a Common Rail Side
  
  *b Injector Side
  
  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.
INSTALL THROTTLE BODY BRACKET (w/o EGR System)
1. Install the throttle body bracket with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Install the gas filter with gas filter bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Connect the vacuum hose.
INSTALL NO. 1 INTAKE PIPE (w/o EGR System)
1. Connect the No. 1 intake pipe with the air hose and install the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 2 clamps of the No. 1 air hose.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. Tighten the clamp of the intercooler air hose.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
4. Connect the vacuum hose to the manifold absolute pressure sensor connector.
5. Connect the 3 connectors to the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.
6. Attach the 2 clamps.
CONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)
1. Connect the No. 4 vacuum transmitting pipe with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT INLET HEATER WATER HOSE (w/o EGR System)
1. Connect the inlet heater water hose with the bolt.
  
  Torque:
  
  26 N*m { 260 kgf*cm, 19 ft.*lbf }
INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)
1. Install the electric EGR control valve assembly Click here.
PERFORM REGISTRATION
1. Perform registration of the injector compensation code Click here.
2. Perform registration of pilot quantity learning Click here.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

Text in Illustration
*1	Yellow Mark
*2	Pink Mark

Text in Illustration
*1	No. 2 Injection Pipe

Text in Illustration
*a	Common Rail Side
*b	Injector Side

ADD ENGINE COOLANT (w/ EGR System with EGR Cooler)

Tighten the radiator drain cock plug by hand.
Tighten the cylinder block drain cock plug.

Torque:

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

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
for Automatic Transmission	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
for Manual Transmission	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

Tech Tips

TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, 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).
Please contact your TOYOTA dealer for further details.
for Cold Area Specification Vehicles:

Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

Note

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level drops below the B line, add TOYOTA SLLC to the B line.
Install the radiator reservoir cap.
Using a wrench, install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
Bleed air from the cooling system.
1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
2. Maintain the engine speed at 2500 to 3000 rpm.
3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
  CAUTION:
  
  When pressing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
4. Stop the engine and wait until the coolant cools down to ambient temperature.
  
  CAUTION:
  
  Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
After the coolant cools down, check that the coolant level is at the FULL line.

If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

BLEED AIR FROM FUEL SYSTEM
1. 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
  
  The maximum hand pump pumping speed is 2 strokes per second.
  
  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. Start the engine.
  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 on (IG) and turn the intelligent tester on.
6. Clear the DTCs Click here.
7. Start the engine.*1
8. 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 5th 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 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.
INSPECT FOR COOLANT LEAK (w/ EGR System with EGR Cooler)

Note

Before each inspection, turn the A/C switch off.

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and check that the pressure does not drop.
  
  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 head.
INSPECT FOR FUEL LEAK
CAUTION:
- During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.
- During Active Test mode, fuel becomes highly pressurized. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.
1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.
2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.
3. Disconnect the return hose from the common rail.
4. Start the engine and check for fuel leaks from the return pipe.
  
  If there is fuel leakage, replace the common rail.
5. Connect the intelligent tester to the DLC3.
6. Start the engine and turn the intelligent tester on.
7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.
8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.
9. Check that there are no leaks from any part of the fuel system.
  
  Note
  
  A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.
  
  If there is fuel leakage, repair or replace parts as necessary.
10. Reconnect the return hose to the common rail.
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 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.
  
  If low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill engine oil above the full level mark.