Fuel Injector (W/ Dpf) 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 one of the O-rings 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 seat surface.
   
2. After installing the injector to the cylinder head, the O-ring may prevent the injector from being fully seated. If so, pull out the injector and reinstall it.
   
3. Always reinstall 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 (HILUX_TGN26 RM0000012XK059X_02_0003.html).

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

NOTICE:

1. The fork portion of the No. 1 nozzle holder clamp must be set on the injector.
   
2. Before tightening the bolts, check that the No. 1 nozzle holder clamps are set properly.
   
3. When installing the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a following step.
   
4. When tightening the bolts, be careful so as not to tilt the bolt or clamp.
   
5. Do not reuse the washer.
   

HINT:

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

Temporarily install the 4 injection pipes with the union nuts.

HINT:

To position the injectors, loosely tighten the union nuts.

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

Tighten the 4 nozzle holder clamp bolts.

Torque:

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

Remove the 4 injection pipes.

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.

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

1. Install a new gasket and the 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 nozzle 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 nozzle leakage pipe connection.
   

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

   NOTICE:

   Never reinstall the disassembled union bolt to the engine.

Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

NOTICE:

1. Do not install the No. 3 cylinder head cover gaskets at an angle.
   
2. Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.
   

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

Apply seal packing to the areas shown in the illustration.

Seal packing:

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

Text in Illustration

Seal Packing

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the cylinder head cover.
   

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

Temporarily install the cylinder head cover with the 10 bolts and 2 nuts in the order shown in the illustration. Then, tighten the 10 bolts and 2 nuts in the order shown in the illustration in 2 progressive steps.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Connect the ventilation hose.

Install 4 new nozzle holder seals.

Install the No. 2 cylinder head cover with the 3 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

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

Text in Illustration

Union Bolt

Temporarily install a new gasket and the union bolt.

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}

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

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

Text in Illustration

Fuel Check Valve

Temporarily install a new gasket and the fuel check valve.

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}

Connect the 3 fuel hoses.

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

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

Text in Illustration

*1	Gasket
*2	No. 1 Fuel Pipe
	Bolt
	Supply Pump Hollow Screw
	Fuel Check Valve
	Union Bolt

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

Temporarily install a new gasket and the fuel check valve.

NOTICE:

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

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

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

Torque:

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

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}

NOTICE:

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

Install the wiring harness clamp bracket with the bolt.

Torque:

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

Attach the wire harness clamp.

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

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

Torque:

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

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 (HILUX_TGN26 RM000004QR1006X.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 (HILUX_TGN26 RM000004QR1006X.html).

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

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

Standard capacity:

9.8 liters (10.4 US qts, 8.6 Imp. qts)

NOTICE:

Never use water as a substitute for engine coolant.

HINT:

1. 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).
   
2. Please contact your TOYOTA dealer for further details.
   

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.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 17 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.
   

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:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. 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.

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.

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.
   

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 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 (HILUX_TGN26 RM000000PDK0X3X.html).

Start the engine.*1

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

Read Current DTCs.

Clear the DTCs (HILUX_TGN26 RM000000PDK0X3X.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 / DTC.

Read Current DTCs.

OK:

No DTCs are output.

Perform registration of the injector compensation codes (HILUX_TGN26 RM0000012XK059X_02_0003.html).

Perform pilot quantity learning (HILUX_TGN26 RM0000012XK059X.html).

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator 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 and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

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 / 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.

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

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.

NOTICE:

Do not fill engine oil above the full level mark.