11–14 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA

MADE FOR ARGENTINA))

1116S–06

REPLACEMENT
NOTICE:
After removing the injection pipes, clean them with a brush and compressed air.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (–) battery terminal to pre-
vent airbag activation.
2. LOOSEN FUEL TANK CAP ASSY
3. REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 14–24)
4. 2KD–FTV:
REMOVE ENGINE COVER BRACKET (See page 14–24)
5. 1KD–FTV:
REMOVE CHARGE AIR COOLER ASSY W/ INTAKE AIR CONNECTOR (See page 13–42)
6. 2KD–FTV:
REMOVE AIR CLEANER PIPE SUB–ASSY NO.2 (See page 14–24)

Injector Side Injection Pipe

7. REMOVE INJECTION PIPE
Clamp No. 2 NOTICE:
S After removing the fuel pipe, cover the outlets on the
SST common rail with tape to keep out foreign matter.
S After removing the fuel pipe, put it in a plastic bag to
prevent foreign matter from contaminating its injec-
tor inlet.
(a) Remove the 2 nuts and injection pipe clamp No. 3.
(b) Remove the bolt and injection pipe clamp No. 2.
(c) Using SST, loosen the union nuts and remove the injec-
Common Rail Side tion pipes No. 1, No. 2 and No. 3.
SST 09023–12701
SST

Injection Pipe
Clamp No. 3
A99022

(1) Remove the 2 bolts and disconnect the 2 injection

pipe clamps.

A98893

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 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA 11–15
MADE FOR ARGENTINA))

Injector Side (2)Using SST, loosen the union nuts and remove the
injection pipe No. 4.
SST 09023–12701

SST

Common Rail Side

SST

G42538

8. REMOVE CYLINDER HEAD COVER SUB–ASSY

(a) Using a small screwdriver, remove the holder seal by pry-
ing the portion between the holder seal and the cutout
part of the cylinder head.
(b) Disconnect the ventilation hose.

A60180

(c) Disconnect the 4 connectors.

G34844

(d) Remove the 10 bolts, 2 nuts, cylinder head cover and

gasket.

G34877

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11–16 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA
MADE FOR ARGENTINA))

9. REMOVE INJECTOR ASSY

(a) Remove the union bolt, 4 hollow screws, 5 gaskets and
nozzle leakage pipe.
NOTICE:
S When removing the nozzle leakage pipe, place a
cushion under the pipe.
S Be careful not to deform or scratch the union seal sur-
face.
A61112 S After removing the fuel pipe, put it in a plastic bag to
prevent foreign matter from contaminating its injec-
tor inlet.

(b) Remove the 4 bolts, 4 washers, 4 nozzle holder clamps

and 4 injectors.
HINT:
Arrange the injectors, holder clamps, washers and bolts in the
correct order.
(c) Remove the O–ring and back–up ring from the injector.
(d) Remove the 4 injection nozzle sheets from the cylinder
head.
G34876

10. INSTALL INJECTOR ASSY

NOTICE:
Be sure to install the injector, holder clamp, washer and
bolt in their original positions.
(a) Install 4 new injection nozzle sheets to the cylinder head.

B08252

(b) Apply a light amount of clean engine oil to 4 new O–rings.

(c) Install an O–ring to each injector as shown in the illustra-
New O–Ring
tion.
(d) Insert the 4 injectors into the cylinder head.
NOTICE:
S At this time, insert the injector until it touches the
nozzle sheet surface.
S After installing the injector to the cylinder head, the
G36760 O–ring may prevent the injector from fully seating. If
so, pull out the injector and reinstall it.
S Always return an injector to the same place it was re-
moved from.
(e) Register injector compensation code (when replacing
with a new injector) (see page 05–32).

HILUX REPAIR MANUAL (Argentina) (DR201E)

 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA 11–17
MADE FOR ARGENTINA))

Washer (f) Temporarily install 4 new washers and the 4 nozzle

Downward clamps with the 4 clamp bolts.
HINT:
Apply a light amount of engine oil to the threads and under the
heads of the clamp bolts.

A60177

NOTICE:
S The fork portion of the nozzle holder clamp must be
set to the injector.
S Before tightening the bolts, check that the nozzle
Nozzle holder clamp is set properly.
Clamp S To fasten the clamp bolts, first tighten them by hand
Holder until they cannot be turned further. Then, tighten the
bolts to the specified torque at following step.
G37744 S When tightening the bolts, pay attention not to tilt the
bolt and the clamp.
S Do not reuse the washer.
S If the nozzle leakage pipe is accidentally tightened be-
yond the torque specification, it must be replaced.
(g) Temporarily install the 4 injection pipes with the union
nuts.
HINT:
To position the injectors, loosely tighten the union nut.

(h) 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.

A62123

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11–18 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA
MADE FOR ARGENTINA))

(i) Set the leakage pipe and 5 new gaskets in place.

Union Bolt (j) Apply a light amount of oil to the 4 hollow screws and
union bolt.

Hollow
Screw

A70538

(k) Temporarily install the leakage pipe with the 4 hollow

screws and union bolt.
(l) Tighten the 4 holder clamp bolts.
Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)
NOTICE:
When tightening the bolts to a specified torque, pay atten-
tion not to tilt the bolt and the clamp.

A60184

Union Bolt
(m) Tighten the 4 hollow screws in order from 1 to 4.
Torque: 16 N·m (163 kgf·cm, 12 ft·lbf)
NOTICE:
If a hollow screw is accidentally tightened beyond the
4 torque specification, it must be replaced.
3 (n) Tighten the union bolt.
2 Torque: 12.5 N·m (127 kgf·cm, 9 ft·lbf)
Hollow Screw 1 NOTICE:
A51297 If the union bolt is accidentally tightened beyond the torque
specification, it must be replaced.
(o) Remove the 4 injection pipes.

11. CHECK FOR FUEL LEAKS

SST
(a) Check that there are no leaks from the nozzle leakage
pipe connection.
(1) Install the gasket and nozzle leakage pipe No. 2 to
the cylinder head with SST (check valve).
Part No. 23762–27010 (Nozzle leakage pipe No. 2)
SST 09992–00242, 09280–00010
Torque: 21 N⋅m (214 kgf⋅cm, 16 ft⋅lbf)
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 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA 11–19
MADE FOR ARGENTINA))

(2) Apply a light 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

SST fuel return side of the leakage pipe, and maintain
250 kPa (2.5 kgf/cm2, 35.5 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.
A60186 (4) After checking for fuel leaks, wipe off the soapy wa-
ter from the leakage pipe connection.
(5) Remove SST, nozzle leakage pipe No. 2 and gas-
ket.
SST 09992–00242, 09280–00010
NOTICE:
Never reinstall the disassembled check valve on the en-
gine.

12. INSTALL CYLINDER HEAD COVER SUB–ASSY

(a) Remove any old seal packing (FIPG) material from the
cylinder head.
(b) Apply seal packing to the specific areas shown in the il-
lustration.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
: Seal Packing A60179 S Install the head cover within 3 minutes after applying
seal packing.
S Do not start the engine for at least 2 hours after instal-
ling the seal packing.

(c) Install the gasket and cylinder head cover with the 10
bolts and 2 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(d) Install 4 new nozzle holder seals.

G34877

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11–20 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA
MADE FOR ARGENTINA))

13. INSTALL INJECTION PIPE

Painted
NOTICE:
Mark
S When replacing the injector, also replace the injection
Approx.
8.0 mm pipe.
(0.31 in.) S Keep the joints of the injection pipe clean.
(a) Temporarily install the injection pipe No. 1, No. 2 and No.
Injection 3 with the union nuts.
Pipe No. 1 (b) Install the injection pipe clamp No. 2 and No. 3 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 injection pipe No. 1 has disappeared,
use the illustration as a reference to install the clamps.

Injection
Injection Pipe
Pipe Clamp
Clamp No. 3
No. 2 G38585

Common Rail Side (c) Using SST, tighten the injection pipe union nuts on the
common rail side.
SST 09023–12701
Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf)
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(d) Using SST, tighten the injection pipe union nuts on the in-
jector side.
SST 09023–12701
30 cm
Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf)
Injector Side
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
SST

30 cm

A98972

(e) Temporarily install the injection pipe No. 4 with the union
nuts.
(f) Install 2 new injection pipe clamps with the 2 bolts.
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
NOTICE:
S Make sure that the inner–rubbers of the injection pipe
fit inside the clamps.
S When installing the pipe, check that the inner–rub-
A98893 bers and the clamps are in their proper positions.

HILUX REPAIR MANUAL (Argentina) (DR201E)

 FUEL – INJECTOR ASSY (HILUX/1KD–FTV, 2KD–FTV (TASA 11–21
MADE FOR ARGENTINA))

Common Rail Side (g) Using SST, tighten the injection pipe union nuts on the
common rail side.
SST 09023–12701
SST Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(h) Using SST, tighten the injection pipe union nuts on the in-
30 cm
jector side.
Injector Side SST 09023–12701
Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf)
30 cm HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

SST

A98973

14. 2KD–FTV:
INSTALL AIR CLEANER PIPE SUB–ASSY NO.2 (See page 14–24)
15. 1KD–FTV:
INSTALL CHARGE AIR COOLER ASSY W/ INTAKE AIR CONNECTOR (See page 13–42)
16. 2KD–FTV:
INSTALL ENGINE COVER BRACKET (See page 14–24)
17. INSTALL ENGINE COVER SUB–ASSY NO.1 (See page 14–24)
18. TIGHTEN FUEL TANK CAP ASSY
19. BLEED AIR FROM FUEL SYSTEM (See page 11–7)
20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
21. REGISTER INJECTOR COMPENSATION CODE (See page 05–32)
22. CHECK FOR FUEL LEAKS
23. CHECK FOR OIL LEAKS

HILUX REPAIR MANUAL (Argentina) (DR201E)