FUEL INJECTOR INSTALLATION

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.


    1. B001EFXE02

      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. B001FAWE10
      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. B001FITE09
      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. B001CXAE11

      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. B001D07E06
      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. B001CQ3E02
      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.

  2. INSPECT FOR FUEL LEAK


    1. B001HB7E03

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


      1. 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 }

      2. Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

      3. B001IDFE04

        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

      4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

      5. Remove SST, the No. 2 nozzle leakage pipe and gasket.

        Note

        Never reinstall the disassembled union bolt to the engine.

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B001F2ZE02
      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.

    2. Remove any old seal packing (FIPG material) from the cylinder head.

    3. B001GZ0E01
      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.

    4. 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 }

    5. Install 4 new nozzle holder seals.

  4. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B001IHKE02

      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.

  5. INSTALL VENTILATION PIPE

    Click here

  6. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  7. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  8. 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. B001GUU

      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. B001E0NE01
      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.

  9. INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE

    Click here

  10. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)

    Click here

  11. CONNECT ENGINE WIRE (w/o EGR System)

    Click here

  12. INSTALL AIR CONNECTOR STAY (w/o EGR System)

    Click here

  13. 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. B001GHME01
      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. B001I04E01
      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.

  14. INSTALL THROTTLE BODY BRACKET (w/o EGR System)

    Click here

  15. INSTALL NO. 1 INTAKE PIPE (w/o EGR System)

    Click here

  16. CONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)

    Click here

  17. CONNECT INLET HEATER WATER HOSE (w/o EGR System)

    Click here

  18. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Install the electric EGR control valve assembly Click here.

  19. PERFORM REGISTRATION


    1. Perform registration of the injector compensation code Click here.

    2. Perform registration of pilot quantity learning Click here.

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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

    Click here

  22. BLEED AIR FROM FUEL SYSTEM

    Click here

  23. INSPECT FOR COOLANT LEAK (w/ EGR System with EGR Cooler)

    Click here

  24. INSPECT FOR FUEL LEAK

    Click here

  25. INSPECT FOR OIL LEAK

    Click here

  26. INSPECT ENGINE OIL LEVEL

    Click here