EXHAUST FUEL ADDITION INJECTOR (for DPF) INSTALLATION


  1. INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Note

    If there is foreign matter on the installation surface of the exhaust fuel addition injector assembly, be sure to clean the exhaust fuel addition injector assembly before installation.


    1. Install a new E-ring, a new O-ring and 3 new backup rings to the exhaust fuel addition injector assembly.

      A003B0IE05
      Text in Illustration
      *1 No. 1 Backup Ring *2 No. 2 Backup Ring
      *3 No. 3 Backup Ring *4 O-Ring
      *5 E-Ring - -
      *a CORRECT *b INCORRECT
      *c Overlapped *d Normal
      *e Stretched - -

      Note


      • Check that there is no foreign matter or damaged areas in the injector O-ring groove.

      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.

      • Make sure that the backup rings and O-ring are installed in the correct order.

      • Check that the alignment openings of the backup rings are not stretched and that the ends of the backup rings are not overlapped as shown in the illustration.

      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

    2. Install a new gasket and the No. 1 injector holder with the 3 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    3. Install a new injection nozzle seat and the exhaust fuel addition injector assembly.

    4. Using a T40 "TORX" socket wrench, install the No. 1 nozzle holder clamp with the screw.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    5. Temporarily install the No. 2 injector holder to the No. 1 injector holder with the 2 bolts.

    6. Tighten the No. 2 injector holder with the 2 bolts.

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

  2. INSTALL TURBINE OUTLET ELBOW

    Click here

  3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  4. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. 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 }
    5. A003EJI

      Add engine coolant up to the B line mark in the radiator reservoir assembly and install the radiator reservoir cap sub-assembly.

    6. 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.

    7. A003FFY

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

  5. 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.

  6. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch to ON.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. 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