1. Toyota 1KD-FTV
Common Rail Diesel Injector
Installation Manual Prado,
Hilux, HiAce
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or reproduced without permission
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2. COMMON RAIL DENSO DIESEL INJECTOR
ENGINE IN
1.1 Disassemble:
1.2 Pre-assemblyPrepar
1.3 Assembly
COMMON RAIL DENSO DIESEL INJECTOR
NSTALL MANUAL 1KD
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ration
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COMMON RAIL DENSO DIESEL INJECTOR
KD-FTV
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3. Disassemble: 1.1
Lift Bonnet
First step, we need to find the bonne
Dash.
Removal of Intercooler Cover
Next step, you need to take your 10
Removal of the Intercooler Cove
Once all the bolts are undone, sim
make sure you have all the bolts ou
Engine Install Manual 1KD-FTV - 1
net release latch in the driver's footwell, a
0mm Socket, and undo the small bolts ho
er
mplylift the cover off. It should come VERY
out.
at the bottom of the
holding down this cover
Yeasily. If it does not,

4. Removal of Intercooler
Next 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 Intercooler
Second Sensor as seen from a different view
Engine Install Manual 1KD-FTV - 2

5. Removal of Intercooler
Lastlyfor the engine side of the intercooler, we need to remove the vacuum / boost tube.
Removal of Intercooler
Next step, just above the turbocharger, you will see this pipe which will have these two
hose clamps attached.
Engine Install Manual 1KD-FTV - 3

6. Removal of Intercooler
Next, we just need to undo the Bolts holding the intercooler in place;
Removal of Intercooler
Now, the onlything left holding the intercooler in place is the pipes that are onlyloosely
connected. To remove, first pull the passenger side back to you, rotating the intercooler around
the intercooler inlet pipe. Once the intercooler outlet is free, lift the Inlet side to completely remove
Engine Install Manual 1KD-FTV - 4

7. the intercooler.
Unplugging Injectors
Now, your vehicle should look like so. From here, the next step is to remove the injector plugs
from the injectors.
*** Please note, this vehicle has a Chip fitted, hence there are 8 plugs visible. Chip or no chip, you
onlyneed to be concerned with the plugs that are physicallyon the injectors.
Engine Install Manual 1KD-FTV - 5

8. Removal of injector harness rail
Now the injectors are unplugged, we need to remove the harness rail connected to the Tappet
cover
Engine Install Manual 1KD-FTV - 6

9. Unplug injector Harness - sensor
Next, we need to unplug the sensor that is attached to the injector harness.
Engine Install Manual 1KD-FTV - 7

10. Injector Supply Pipes Removal
After you've undone the sensor and moved the Injector harness out of the way (along the fire wall
is a good place) next we need to undo the injector supplypipes.
Injector Pipes Removal
Next you will need to simplyclear the injector pipe nuts from their seal bypulling them back (by
hand) so that theyare fullyvisible.
Engine Install Manual 1KD-FTV - 8

11. Injector Pipe removal
Next we need to free the pipes up; to do this, we need to loosen these brackets. There's a
second bracket obscured in the back.
Injector Pipe removal
Lastly, to loosen the injector pipes, we need to undo the 'other' (rail) end of the pipe. In this photo
you can see where the front two pipes connect to the rail. Obviously, there are another two further
back that will also need to be loosened.
Engine Install Manual 1KD-FTV - 9

12. Injector pipe removal
Here you can now see that we are able to pull back on the pipes and have enough clearance that
it will clear the tappet assembly. This is as far as we need to go, if you are planning to reuse the
old injector lines.
*** IT'S EXTREMELY important that you do not 'flex' or 'bend' these pipes. Otherwise replacement
reallywould be necessary.
Engine Install Manual 1KD-FTV - 10

13. Tappet Cover Removal
Next step is to remove the tappet cover. Firstly, we need to remove the injector inlet cups. To do
this, you will notice a s m all cut-out (usually at the top) where you will be able to GENTLY put the
end of a flat blade Screw Driver. Once this is done, you will be able to twist the screw driver and
then 'pop' these cups out.
Engine Install Manual 1KD-FTV - 11

14. Tappet cover removal
Next step is to unscrew all of the bolts that are holding the tappet cover down. There are more
than are visible in this photo.
Engine Install Manual 1KD-FTV - 12

15. Tappet Cover Removal
Next step is to disconnect the crank case breather pipe.
Engine Install Manual 1KD-FTV - 13

16. Tappet Cover Removal
Next is to physicallyremove the tappet cover. To do this, first you need to lift the tappet cover over
the injector tops, and then 'slide' it out towards the driver's side.
Engine Install Manual 1KD-FTV - 14

17. Injector Removal
First step of the injector removal is to loosen and remove the bolts that are in the leak off rail to the
injector.
Engine Install Manual 1KD-FTV - 15

18. Leak off bolt removal
This is what the Leakoff bolt and washer should look like. It is possible to re-use the alloy one like
shown (limited number of times), but the copper ones should be replaced everytime.
Engine Install Manual 1KD-FTV - 16

19. Leak off rail loosening
Last step is to loosen the leak off rail main fitting bolt at the back of the head, slightly off to the
passenger side of the car. It does not need to be removed, just loosened.
Engine Install Manual 1KD-FTV - 17

20. Leak off rail Loosened
Now you should be able to 'swing' the leak off rail out and away from the injectors.
Injector Removal
Next step is to loosen the stretch bolt that is holding the injector clamp down plate. Obviously, you
will 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. cylinder 1 is different to the rest, but if you take the approach that everything goes back to the
same location, you shouldn't have a problem.
Clamp Down Plates + Stretch Bolts
This is what the Stretch bolts and clamp down plates should look like.
Engine Install Manual 1KD-FTV - 19

22. Injector Removal
Next step is to remove the injectors. We usuallyjust put a screw driver between the injector inlet
and the CAST FINISHED part of the cam (directlyunderneath) and then just lightlyand carefully
lever the injector out. If theyare very hard to move, you may need to call a professional with an
injector puller - but most times, it's not required.
Engine Install Manual 1KD-FTV - 20

23. Injectors are now out
Now the injectors are out, you need to take some pre-cautionary measures. You have your
cylinder open now, so it's best (especiallyif you're leaving it alone for some time) to put
something 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. The following sections can be downloaded for
free..
Section 1.2 – Pre-Assembly
Section 1.3 - Assembly
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