Toyota 1KD-FTV Common Rail Diesel Injector Installation Manual


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Toyota 1KD-FTV Common Rail Diesel Injector Installation Manual

  1. 1. Toyota 1KD-FTVCommon Rail Diesel InjectorInstallation Manual Prado,Hilux, HiAceAll Rights Reserved – Not to be copied, distributedor reproduced without
  3. 3. Disassemble: 1.1Lift BonnetFirst step, we need to find the bonneDash.Removal of Intercooler CoverNext step, you need to take your 10Removal of the Intercooler CoveOnce all the bolts are undone, simmake sure you have all the bolts ouEngine Install Manual 1KD-FTV - 1net release latch in the drivers footwell, a0mm Socket, and undo the small bolts hoermplylift the cover off. It should come the bottom of theholding down this coverYeasily. If it does not,
  4. 4. Removal of IntercoolerNext step, we need to remove the intercooler, as the injectors are situated underneath. To do this,you will need to start by loosening off this hose clamp; You will also need to remove two sensors:Removal of IntercoolerSecond Sensor as seen from a different viewEngine Install Manual 1KD-FTV - 2
  5. 5. Removal of IntercoolerLastlyfor the engine side of the intercooler, we need to remove the vacuum / boost tube.Removal of IntercoolerNext step, just above the turbocharger, you will see this pipe which will have these twohose clamps attached.Engine Install Manual 1KD-FTV - 3
  6. 6. Removal of IntercoolerNext, we just need to undo the Bolts holding the intercooler in place;Removal of IntercoolerNow, the onlything left holding the intercooler in place is the pipes that are onlylooselyconnected. To remove, first pull the passenger side back to you, rotating the intercooler aroundthe intercooler inlet pipe. Once the intercooler outlet is free, lift the Inlet side to completely removeEngine Install Manual 1KD-FTV - 4
  7. 7. the intercooler.Unplugging InjectorsNow, your vehicle should look like so. From here, the next step is to remove the injector plugsfrom the injectors.*** Please note, this vehicle has a Chip fitted, hence there are 8 plugs visible. Chip or no chip, youonlyneed to be concerned with the plugs that are physicallyon the injectors.Engine Install Manual 1KD-FTV - 5
  8. 8. Removal of injector harness railNow the injectors are unplugged, we need to remove the harness rail connected to the TappetcoverEngine Install Manual 1KD-FTV - 6
  9. 9. Unplug injector Harness - sensorNext, we need to unplug the sensor that is attached to the injector harness.Engine Install Manual 1KD-FTV - 7
  10. 10. Injector Supply Pipes RemovalAfter youve undone the sensor and moved the Injector harness out of the way (along the fire wallis a good place) next we need to undo the injector supplypipes.Injector Pipes RemovalNext you will need to simplyclear the injector pipe nuts from their seal bypulling them back (byhand) so that theyare fullyvisible.Engine Install Manual 1KD-FTV - 8
  11. 11. Injector Pipe removalNext we need to free the pipes up; to do this, we need to loosen these brackets. Theres asecond bracket obscured in the back.Injector Pipe removalLastly, to loosen the injector pipes, we need to undo the other (rail) end of the pipe. In this photoyou can see where the front two pipes connect to the rail. Obviously, there are another two furtherback that will also need to be loosened.Engine Install Manual 1KD-FTV - 9
  12. 12. Injector pipe removalHere you can now see that we are able to pull back on the pipes and have enough clearance thatit will clear the tappet assembly. This is as far as we need to go, if you are planning to reuse theold injector lines.*** ITS EXTREMELY important that you do not flex or bend these pipes. Otherwise replacementreallywould be necessary.Engine Install Manual 1KD-FTV - 10
  13. 13. Tappet Cover RemovalNext step is to remove the tappet cover. Firstly, we need to remove the injector inlet cups. To dothis, you will notice a s m all cut-out (usually at the top) where you will be able to GENTLY put theend of a flat blade Screw Driver. Once this is done, you will be able to twist the screw driver andthen pop these cups out.Engine Install Manual 1KD-FTV - 11
  14. 14. Tappet cover removalNext step is to unscrew all of the bolts that are holding the tappet cover down. There are morethan are visible in this photo.Engine Install Manual 1KD-FTV - 12
  15. 15. Tappet Cover RemovalNext step is to disconnect the crank case breather pipe.Engine Install Manual 1KD-FTV - 13
  16. 16. Tappet Cover RemovalNext is to physicallyremove the tappet cover. To do this, first you need to lift the tappet cover overthe injector tops, and then slide it out towards the drivers side.Engine Install Manual 1KD-FTV - 14
  17. 17. Injector RemovalFirst step of the injector removal is to loosen and remove the bolts that are in the leak off rail to theinjector.Engine Install Manual 1KD-FTV - 15
  18. 18. Leak off bolt removalThis is what the Leakoff bolt and washer should look like. It is possible to re-use the alloy one likeshown (limited number of times), but the copper ones should be replaced everytime.Engine Install Manual 1KD-FTV - 16
  19. 19. Leak off rail looseningLast step is to loosen the leak off rail main fitting bolt at the back of the head, slightly off to thepassenger side of the car. It does not need to be removed, just loosened.Engine Install Manual 1KD-FTV - 17
  20. 20. Leak off rail LoosenedNow you should be able to swing the leak off rail out and away from the injectors.Injector RemovalNext step is to loosen the stretch bolt that is holding the injector clamp down plate. Obviously, youwill need to do the same for all injectors.*** Make sure that you know which clamp down plate goes to which cylinder. In some vehicles,Engine Install Manual 1KD-FTV - 18
  21. 21. cylinder 1 is different to the rest, but if you take the approach that everything goes back to thesame location, you shouldnt have a problem.Clamp Down Plates + Stretch BoltsThis is what the Stretch bolts and clamp down plates should look like.Engine Install Manual 1KD-FTV - 19
  22. 22. Injector RemovalNext step is to remove the injectors. We usuallyjust put a screw driver between the injector inletand the CAST FINISHED part of the cam (directlyunderneath) and then just lightlyand carefullylever the injector out. If theyare very hard to move, you may need to call a professional with aninjector puller - but most times, its not required.Engine Install Manual 1KD-FTV - 20
  23. 23. Injectors are now outNow the injectors are out, you need to take some pre-cautionary measures. You have yourcylinder open now, so its best (especiallyif youre leaving it alone for some time) to putsomething over the head to stop (as best as you can) any foreign material getting into the engine.Disassembly is now complete.Engine Install Manual 1KD-FTV - 21
  24. 24. The following sections can be downloaded forfree..Section 1.2 – Pre-AssemblySection 1.3 - AssemblyBy visiting our Facebook directly from our website: