Exhaust Fuel Addition Injector Installation

Install a new No. 1 fuel injector back-up ring, No. 2 fuel injector back-up ring, O-ring and No. 3 fuel injector back-up ring to the exhaust fuel addition injector assembly.

Install a new E-ring to the exhaust fuel addition injector assembly.

Install a new gasket and the exhaust fuel addition injector assembly to the No. 1 injector holder.

Using a T40 "TORX" socket wrench, install the No. 2 nozzle holder clamp with the bolt.

Torque:

12 N*m{117 kgf*cm, 8 ft.*lbf}

Install the injector holder to the No. 1 injector holder with the 2 bolts.

Torque:

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

Install a new gasket and the No. 2 exhaust manifold heat insulator to the No. 1 injector holder with the 3 nuts.

Torque:

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

Install the No. 1 injector holder to the exhaust manifold with 3 new nuts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Connect the connector to the exhaust fuel addition injector assembly.

Connect the No. 5 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.

Connect the No. 4 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.

Connect the PCV pipe to the compressor inlet elbow, cylinder head cover sub-assembly and slide the 2 hose clips to secure the hoses.

Install the PCV pipe with the bolt to the compressor inlet elbow.

Torque:

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

Connect the No. 19 water by-pass hose to the compressor inlet elbow and slide the hose clip to secure the hoses.

Install the No. 20 water by-pass hose to the PCV pipe and No. 1 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Connect the No. 1 fuel pipe to the No. 4 fuel pipe.

Install a new gasket and the No. 1 fuel pipe to the cylinder head cover sub-assembly and No. 1 injector holder with the union bolt and bolt.

Torque:

for bolt:

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

for union bolt:

26 N*m{265 kgf*cm, 19 ft.*lbf}

While pushing the No. 1 engine cover sub-assembly towards the rear, attach the 2 rear pins.

Attach the 2 front clips to install the No. 1 engine cover sub-assembly.

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

NOTICE:

1. The maximum hand pump pumping speed is 2 strokes per second.
   
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.
   

Check if the engine starts.

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 air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the engine switch off.

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   
2. w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.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 5th 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 /Trouble Codes.

Read Current DTCs.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.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 / Trouble Codes.

Read Current DTCs.

OK:

No DTCs are output.

Add engine coolant through the radiator reservoir filler opening until the engine coolant reaches the "B" line.

Standard Capacity:

Item		Specified Condition
for Manual Transmission	except Cold Area Specification Vehicle	10.1 liters (10.7 US qts, 8.9 Imp. qts)
	for Cold Area Specification Vehicle	11.9 liters (12.6 US qts, 10.5 Imp. qts)
for Automatic Transmission	except Cold Area Specification Vehicle	10.0 liters (10.6 US qts, 8.8 Imp. qts)
	for Cold Area Specification Vehicle	11.8 liters (12.5 US qts, 10.4 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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 is a combination of low phosphates and organic acids).

Press the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
If the coolant level drops below the B line, add engine coolant to the B line.

Install the radiator reservoir cap sub-assembly.

Using a wrench, install the vent plug.

Torque:

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

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.
   

   NOTICE:

   1. Immediately after starting the engine, if the radiator reservoir sub-assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.
      
   2. Do not start the engine when there is no coolant in the radiator reservoir sub-assembly.
      
   3. Make sure that the needle does not show an abnormally high temperature.
      
   4. If there is not enough coolant, the engine may overheat.
      

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

2. Maintain the engine speed at 2000 to 2500 rpm.
   

3. Press the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
   

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

Check the coolant level in the radiator reservoir sub-assembly.
If the coolant level is low, add engine coolant to the radiator reservoir sub-assembly full line.

Remove the radiator reservoir cap sub-assembly.

Fill the radiator assembly with engine coolant and attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.
If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.

Remove the radiator cap tester and install the radiator reservoir cap sub-assembly.