Contents: Removal ↓ Installation ↓
Faulty injectors are the cause of loud knocking in the engine and damage to the bearings. To find a faulty injector, let the engine idle and sequentially, one by one, loosen the union nuts of the pump fuel lines. If the knocking disappears when loosening one of the nuts, this injector is faulty.
Another way to find a faulty injector is to loosen the union nuts of the fuel lines one by one. If the engine speed increases when you loosen the nut, this indicates that the injector is working properly. If the speed does not increase, this indicates that the injector is faulty.
The injector can also be checked using a pressure gauge (work of a specialized workshop. The injection pressure should be 125-138 bar).
Signs of a faulty injector are:
- No spontaneous combustion.
- Knocking in one or more cylinders.
- Engine overheating.
- Engine power loss.
- Smoke from the exhaust.
- High fuel consumption.
Removal
Flush the fuel supply and return lines with cleaner or diesel fuel.
Remove the high-pressure fuel lines. To do this, loosen the union nuts on the pump and injectors.
Caution: Do not change the shape of the pipelines.
Disconnect the fuel hose from the fuel return line, loosen the locknuts and remove the gaskets and fuel return line.
Remove the injectors using the special key SST 09268-64010 and arrange them in the order in which they were installed.
Remove the rings and gaskets from the holes for the injectors.
Clamp the nozzle in a vice with soft jaws and disassemble it.
Check the injector needle for damage where it contacts the nozzle. Clean the sprayer from carbon deposits.
Caution: Never file or sand the nozzle or needle. Do not interchange nozzle parts.
Installation
Install new gaskets and rings under the injectors.
The original can be viewed on the website: ToyotaMAN
Install the injectors with holders and tighten with special tool SST-09268-64010 with a force of 65 Nm.
Caution: Overtightening the nozzle holder may cause deformation of the nozzle and, as a result, the needle may become stuck.
Connect the fuel return line with new gaskets and tighten the nuts to 30 Nm.
Connect the high-pressure fuel lines. Tighten the union nuts to 30 Nm.
Slightly loosen the union nuts on the injector holders.
Turn the engine with the starter until fuel appears in the area of the union nuts. Tighten the union nuts to the specified torque.