FUEL INJECTOR(w/o DPF) INSTALLATION

CAUTION / NOTICE / HINT

Note

When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.

PROCEDURE


  1. INSTALL FUEL INJECTOR LH

    Note

    Be sure to install the injector, holder clamp and bolt to their original positions.


    1. B001XTI

      Install 4 new injection nozzle seats to the cylinder head.

    2. B001Y7PE04
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of clean engine oil to 4 new O-rings.

    3. Install 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 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.

    6. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

      Note


      • B001WMRE08

        The fork portion of the nozzle holder clamp must be set on the injector.

      • Before tightening the bolts, check that the 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 later step.

      • When tightening the bolts, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *a Downward
    7. B001WBH

      Temporarily install the common rail LH with the 2 bolts.

    8. B001WP6

      Temporarily install 4 new injection pipes to the common rail and injector.

    9. B001ZGHE06
      Text in Illustration
      *1 Nozzle Leakage Pipe

      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.

    10. Set the leakage pipe and 5 new gaskets in place.

    11. B001XWW

      Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

      Text in Illustration
      B001WGT Union Bolt

      Tech Tips

      To position the injectors, loosely tighten the 4 hollow screws and union bolt.

    12. Tighten the 4 holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    13. Remove the 4 injection pipes.

    14. Remove the 2 bolts and common rail LH.

    15. B001XPH

      Tighten the 4 hollow screws.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

    16. B001Z7T

      Tighten the union bolt.

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

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

  2. INSTALL FUEL INJECTOR RH

    Note

    Be sure to install the injector, holder clamp and bolt to their original positions.


    1. B001XTI

      Install 4 new injection nozzle seats to the cylinder head.

    2. B001Y7PE04
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of clean engine oil to 4 new O-rings.

    3. Install 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 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.

    6. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

      Note


      • B001WMRE08

        The fork portion of the nozzle holder clamp must be set on the injector.

      • Before tightening the bolts, check that the 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 later step.

      • When tightening the bolts, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *a Downward
    7. B001WP6

      Temporarily install 4 new injection pipes to the common rail and injector.

    8. B001ZGHE06
      Text in Illustration
      *1 Nozzle Leakage Pipe

      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. Set the leakage pipe and 5 new gaskets in place.

    10. B001XF1

      Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

      Text in Illustration
      B001WGT Union Bolt

      Tech Tips

      To position the injectors, loosely tighten the 4 hollow screws and union bolt.

    11. Tighten the 4 holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    12. Remove the 4 injection pipes.

    13. B001Z5S

      Tighten the 4 hollow screws.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

    14. B001XNI

      Tighten the union bolt.

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

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

  3. INSTALL NOZZLE HOLDER GASKET RH


    1. B001WG8E02
      Text in Illustration
      *1 Nozzle Holder Gasket

      Press 4 new nozzle holder gaskets into the cylinder head cover RH.

      Note

      After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. B001YFJ

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001XPG Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    2. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. B001XCHE01

      Temporarily install the cylinder head cover with the 18 bolts. Tighten the 18 bolts in the order shown in the illustration.

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

      Tech Tips

      After tightening the bolts, check that the bolts at step 11 and 20 are tightened to the specified torque.

  5. INSTALL NOZZLE HOLDER SEAL RH


    1. Press 4 new holder seals into the cylinder head cover RH.

  6. INSTALL CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)


    1. Install the cylinder head cover silencer with the 3 bolts.

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

  7. INSTALL NO. 2 VENTILATION HOSE

  8. INSTALL NOZZLE HOLDER GASKET LH


    1. B001WG8E02
      Text in Illustration
      *1 Nozzle Holder Gasket

      Press 4 new nozzle holder gaskets into the cylinder head cover LH.

      Note

      After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

  9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B001W2F

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001XPG Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    2. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. B001YVCE02

      Temporarily install the cylinder head cover with the 17 bolts. Tighten the 17 bolts in the order shown in the illustration.

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

      Tech Tips

      After tightening the bolts, check that the bolts at step 11 and 19 are tightened to the specified torque.

  10. INSTALL OIL SEPARATOR ASSEMBLY


    1. Install a new gasket to the oil separator.

      Note

      Remove any oil from the contact surface.

    2. Install the oil separator with the 3 bolts.

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

  11. INSTALL NOZZLE HOLDER SEAL LH


    1. Press 4 new holder seals into the cylinder head cover LH.

  12. INSTALL CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)


    1. Install the cylinder head cover silencer with the 3 bolts.

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

  13. INSTALL NO. 3 VENTILATION HOSE

  14. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the vacuum transmitting pipe with the 3 bolts.

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

    2. w/ Intercooler:

      Connect the 2 vacuum hoses.

  15. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for Engine Mounting)


    1. Install the vacuum switching valve with the bolt.

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

    2. Connect the 2 vacuum hoses.

  16. INSTALL NO. 2 ENGINE WIRE

    Click here

  17. INSTALL INJECTION PIPE RH

    Click here

  18. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  19. INSTALL COMMON RAIL ASSEMBLY LH

    Click here

  20. INSTALL INJECTION PIPE LH

    Click here

  21. INSTALL NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  22. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  23. CONNECT ENGINE WIRE

    Click here

  24. INSTALL NO. 4 WATER BY-PASS PIPE

    Click here

  25. INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  26. CONNECT FUEL HOSE

  27. INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  28. INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  29. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  30. INSTALL NO. 4 AIR TUBE

    Click here

  31. INSTALL NO. 2 AIR HOSE

    Click here

  32. INSTALL NO. 3 AIR TUBE

    Click here

  33. INSTALL INTAKE AIR CONNECTOR

    Click here

  34. TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

    Click here

  35. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  36. INSTALL DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  37. INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  38. INSTALL NO. 1 GAS FILTER

    Click here

  39. INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)

    Click here

  40. INSTALL AIR TUBE SUB-ASSEMBLY LH

    Click here

  41. INSTALL CLUTCH HOSE (for Manual Transmission)

    Click here

  42. INSTALL DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  43. INSTALL AIR TUBE SUB-ASSEMBLY RH

    Click here

  44. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  45. CONNECT WATER HOSE SUB-ASSEMBLY

  46. INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)

    Click here

  47. INSTALL NO. 1 COOL AIR INLET (w/o Intercooler)

    Click here

  48. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  49. BLEED CLUTCH LINE (for Manual Transmission)

    Click here

  50. INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)

  51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.

  52. REGISTER INJECTOR COMPENSATION CODE

    Click here

  53. ADD ENGINE COOLANT

    Click here

  54. INSPECT FOR COOLANT LEAK

    Click here

  55. INSPECT FOR FUEL LEAK

    Click here

  56. INSPECT FOR OIL LEAK

    Click here

  57. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  58. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  59. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  60. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here