Fuel Injector Installation

Install 4 new injection nozzle seats to the cylinder head.

Apply a small amount of clean engine oil to 4 new O-rings.

Install an O-ring to each injector as shown in the illustration.

Insert the 4 injectors into the cylinder head.

NOTICE:

1. Insert the injector until it touches the injection nozzle seats surface.
   
2. 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.
   
3. Always return an injector to the same place it was removed from.
   

For an injector that has been replaced with a new injector, register the injector compensation code (Toyota Fortuner RM0000012XK04BX_02_0003.html).

Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

HINT:

Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.

NOTICE:

1. The fork portion of the nozzle holder clamp must be set to the injector.
   
2. Before tightening the bolts, check that the No. 1 nozzle holder clamp is set properly.
   
3. To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque at the following step.
   
4. When tightening the bolts, pay attention not to tilt the bolt and the clamp.
   
5. Do not reuse the washer.
   
6. If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.
   

Temporarily install the 4 injection pipes with the union nuts.

HINT:

To position the injectors, loosely tighten the union nut.

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.

Set the leakage pipe and 5 new gaskets in place.

Apply a small amount of oil to the 4 injector hollow screws and union bolt.

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

Tighten the 4 holder clamp bolts.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Tighten the 4 injector hollow screws in order from 1 to 4.

Torque:

16 N*m{163 kgf*cm, 12 ft.*lbf}

NOTICE:

If an injector hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

Tighten the union bolt.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

NOTICE:

If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

Remove the 4 injection pipes.

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)
   

   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. Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 100 kPa (1.0 kgf/cm², 14.5 psi) of pressure for 60 seconds to check that no bubbles form.
   

   SST

   09992-00242
   

   NOTICE:

   Before checking the leakage, be sure to remove the ball and spring in the check valve.

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

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

   NOTICE:

   Never reinstall the disassembled check valve on the engine.

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

Apply seal packing to the specific areas shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the head cover within 3 minutes after applying seal packing.
   
3. 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.

Connect the ventilation hose.

Connect the 4 connectors and install the 3 bolts.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

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

Temporarily install a new gasket and the union bolt.

Tighten the 3 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}

Connect the 3 fuel hoses.

Temporarily install the No. 4 injection pipe with the union nuts.

Install the 2 bolts.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

NOTICE:

1. If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
   
2. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   
3. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.
   

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}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

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}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

Torque:

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

HINT:

If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

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}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

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}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Perform registration of injector compensation code (Toyota Fortuner RM0000012XK04BX_02_0003.html).

Perform registration of pilot quantity learning (Toyota Fortuner RM0000012XK04BX.html).

Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

NOTICE:

1. Hand pump pumping speed: Max. 2 strokes/ sec.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. 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.
   
5. 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.
   
6. 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.
   

Start the engine.

NOTICE:

1. 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.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. 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.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch to ON and turn the intelligent tester on.

Clear the DTCs (Toyota Fortuner RM0000012WY005X.html).

Start the engine.*1

Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

HINT:

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.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

Clear the DTCs (Toyota Fortuner RM0000012WY005X.html).

HINT:

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.

Repeat steps *1 to *3.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

OK:

No DTCs are output.

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.

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.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and push the intelligent tester main switch on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

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.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.

Warm up the engine, stop the engine and wait for 5 minutes. The oil level should be between the dipstick's low and full level marks.
If the oil level is low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not add engine oil above the full level mark.