COMMON RAIL (for 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.

  • When replacing the common rail, do not remove the foreign object mixing prevention caps of the common rail until just before the fuel inlet pipe and injection pipe are connected to the common rail.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    2. Connect the pressure discharge valve connector.

  2. 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. A01DY82E02

      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:
        12 N*m  { 122 kgf*cm, 9 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.

  3. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01E159E01

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

      Text in Illustration
      A01DZ8Z Union Bolt

    2. Temporarily install a new gasket and the union bolt.

    3. Tighten the 2 bolts and union bolt.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  4. INSTALL NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DZNUE01
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. A01DZSF

      Temporarily install the No. 3 nozzle leakage pipe with the 2 bolts.

      Text in Illustration
      A01DZ8Z Fuel Check Valve

    3. Temporarily install a new gasket and the fuel check valve.

    4. Tighten the 2 bolts and fuel check valve.

      Torque:
      for bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    5. Connect the 3 fuel hoses.

  5. INSTALL NO. 2 FUEL PIPE


    1. A01DYLJE01
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. A01DW1SE01
      Text in Illustration
      *1 Gasket
      *2 No. 1 Fuel Pipe
      A01E2TX Bolt
      A01DZ8Z Supply Pump Hollow Screw
      A01E01H Fuel Check Valve
      A01DXHC Union Bolt

      Temporarily install the No. 2 fuel pipe with the 3 bolts.

    3. Install a new gasket to the No. 1 fuel pipe and temporarily install the union bolt.

    4. Temporarily install a new gasket and the fuel check valve.

      Note

      When temporarily installing the fuel check valve, position the gasket as shown in the illustration.

    5. Temporarily install a new gasket and the supply pump hollow screw.

    6. Using a 6 mm hexagon wrench, tighten the supply pump hollow screw.

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

    7. Tighten the 3 bolts, fuel check valve and union bolt.

      Torque:
      for bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }
      for union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      When tightening the fuel check valve, replace the gasket if it becomes deformed.

  6. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 128 kgf*cm, 9 ft.*lbf }

    2. Attach the wire harness clamp.

  7. 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 2 No. 2 injection pipe clamps with the bolt and nut.

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

    3. 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.

  8. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

    Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  10. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01DYVNE01

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

      Standard capacity
      9.8 liters (10.4 US qts, 8.6 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).

      Note

      Never use water as a substitute for engine coolant.

    4. 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.

    5. Install the radiator reservoir cap.

    6. A01DY58E01

      Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. 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.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

      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.

    8. A01E2D9E01

      After the coolant cools down, check that the coolant level is at the F line.

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

  11. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      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


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • 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. Check if the engine starts.

      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 to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DVKYE05
      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 fifth time.

      A01DYT1E05

      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.

  12. INSPECT FOR COOLANT LEAK

    Note

    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. A01E06UE01

      Fill the radiator with coolant and attach a radiator cap tester to the radiator reservoir.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2,17.1 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 cylinder block and head.

  13. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Turn the intelligent tester on.

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

      5. Perform the Active Test.

        Intelligent Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurize common rail interior and check for fuel leaks Stop/Start

        • The fuel pressure inside the common rail increases to the specified value and the engine speed increases to 2000 rpm when the Active Test is performed.

        • The above conditions are maintained while the Active Test is being performed.

  14. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  15. 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.