injector installation (4JK1-TCY) Page 1 of 6

Injector installation (4JK1-TCY)

1. Component views

Injector

Part name

1. Injector
2. Injector clamp
3. Injector clamp bolt
4. Injector leak-off hose
5. Leak-off pipe and clip
6. Pin
7. Injection pipe
8. Common rail (fuel rail)
9. Fuel supply pump

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injector installation (4JK1-TCY) Page 2 of 6

Tightening torque

1: 26 N・m { 2.7 kgf・m / 19 lb・ft }

2: 44 N・m { 4.5 kgf・m / 32 lb・ft }

3: 7.8 N・m { 0.8 kgf・m / 69 lb・in }

2. Injector installation

1) Apply engine oil to the O-ring.

2) Install the O-ring to the injector.

Caution
• Do not reuse the following parts.

• Clip
• Injector gasket
• O-ring

1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Injector gasket

3) Install the injector gasket to the cylinder head.

Caution
• Clean the cylinder head and injector of any foreign material and dirt before assembling the injector
gasket.
• Do not forcibly push the injector gasket into the injector as it will be pushed until it hits the end of the
injector during clamp tightening.

4) Apply engine oil to the threaded portions and bearing surfaces of the injector clamp tightening bolts.

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injector installation (4JK1-TCY) Page 3 of 6

1. Injector
2. Injector clamp tightening bolt
3. Injector clamp

5) Install the injector and injector clamp to the cylinder head.

Caution
• Check that the injector gasket is installed to the cylinder head.

6) Temporarily tighten the injector clamp tightening bolt to the cylinder head.

1. When replacing the injector

Erase the old cylinder number ID code on the Injector ID Code label attached to the cylinder head cover with a
black pen, etc.

Label on the cylinder head cover (Sample)

1. No. 1 cylinder Injector ID Code

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injector installation (4JK1-TCY) Page 4 of 6

1) Record the Injector ID Code of the new injector.

Note
• Record the 24 characters of the injector ID plate.

The correct order of the ID codes shown in the following injector illustration is as follows.
72 04 F9 F8 F0 00 F0 E7 09 F6 F9 96

Injector ID Code label (Sample)

1. Injector ID Code
2. Injector

3. Injection pipe installation

1) Lightly apply engine oil to the outer circumference of the injector side sleeve nut on the injection pipe.

2) Temporarily tighten the injection pipe lightly with an open-end wrench until it attaches securely to the common
rail (fuel rail).

Caution
• Do not reuse the injection pipe.

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injector installation (4JK1-TCY) Page 5 of 6

3) Tighten the injection pipe to the injector by hand until it can no longer turn.

4) Final tighten the injector clamp tightening bolt to the cylinder head.

Tightening torque: 26 N・m { 2.7 kgf・m / 19 lb・ft }

5) Securely tighten the injection pipe to the injector.

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } Injector side sleeve nut

6) Securely tighten the injection pipe to the common rail (fuel rail).

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } Common rail (fuel rail) side sleeve nut

7) Install the clip to the inlet manifold.

Tightening torque: 7.8 N・m { 0.8 kgf・m / 69 lb・in }

4. Oil level gauge guide tube installation

1) Install the oil level gauge guide tube to the crankcase and inlet manifold.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

2) Connect the oil hose to the crankcase.

3) Install the oil level gauge to the oil level gauge guide tube.

5. Camshaft installation

Refer to "1.Engine 1B.Mechanical(4JK1-TCY) camshaft installation".

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injector installation (4JK1-TCY) Page 6 of 6

6. ECM setting

1. Injector ID Code programming

Note
• If the injector is replaced, perform the Injector ID Code programming.

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

• Diagnostics
• Engine
• 4JK1
• Programming
• Injector ID Code
• Program Injector ID Code

4) Program the Injector ID Code into the ECM by following the on-screen instructions.

5) After the programming is completed, turn the ignition switch OFF for 30 seconds.

2. ECM learned value clear

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

• Diagnostics
• Engine
• 4JK1
• Actuator Test
• Reset Small Fuel Injection Quantity Learning

4) Perform the ECM learned value clear by following the on-screen instructions.

5) After the learned value clear is complete, turn OFF the ignition switch for 30 seconds.

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