COMMON RAIL INJECTOR REPAIR 2kd 1kd ENGINE INJECTOR TOYOTA HILUX DIESEL ENGINE INJECTOR

Here is a clear and useful guide for Toyota 1KD-FTV / 2KD-FTV Common-Rail Injector repair and checking.
(Common in Hilux, Fortuner, Hiace)


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✅ 1KD / 2KD Common Rail Injector Repair Guide

1. Common Symptoms of Injector Problems

Hard starting (especially cold start)

White or black smoke

Knocking / rattling sound

Poor power and pickup

Excessive fuel consumption

Injector correction values out of range

Diesel knock when engine is warm



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✅ 2. Basic Injector Checks Before Repair

A. Resistance (Ohm) Test

Use a multimeter:

Expect: 1.1 – 1.4 Ω
If out of range → coil faulty → injector must be replaced.


B. Leak-off Test (Return Flow Test)

Run the engine for 1 minute with 4 test bottles:

All four bottles should have similar diesel level.

If one has too much return → injector worn.

If one has zero return → nozzle blocked.


C. Spray Pattern / Pop Test

CR injectors do not use normal pop testers, but specialized CR testers.
You're looking for:

Good atomization

No dribbling

Correct fuel quantity
If spray dribbles → nozzle worn → replace.



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✅ 3. Injector Repair Steps (Workshop Procedure)

⚠ CR injectors are very sensitive; do this only if you have proper tools.

Step 1: Disassemble

Remove nozzle

Remove shim

Remove valve plate & control valve

Clean internal body with ultrasonic cleaner


Step 2: Replace Worn Parts

Use original or good-quality repair kits:

Nozzle

Control valve set

Shim kit

O-rings

Filter

Copper washer (important)


Note: If control valve seat is worn → injector cannot be repaired properly.

Step 3: Reassemble & Set Shim

Shim thickness adjusts injector fuel quantity.
Wrong shim = high return, knocking, or poor power.


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✅ 4. Calibration (Very Important!)

After repair, injector must be tested and calibrated on a CR test bench:

Pilot injection

Main injection

Back leakage

Response time

Solenoid current

Injection quantity at 4–6 pressures


If values match standard → test bench prints ID code (QR code).

ID Code Programming

After installing in the engine:

Use Techstream, Launch, or G-Scan

Input 30-digit ID code

Reset pilot learn values


Without coding, engine will knock or vibrate.


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✅ 5. Installation Tips

Always install new copper washer.

Torque injector clamp: 34 Nm

Tighten high-pressure pipe: 30 Nm

Prime the pump before starting.

After first start, check for leak at return line.



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✅ 6. When Injector Cannot Be Repaired?

Replace the injector if:

Control valve seat worn

Electric coil burnt

Injector body scratched

Nozzle seat damaged

ID code cannot be generated



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❓ If you want, tell me:

Your injector code (Denso 095000-xxxx)
and I’ll give you:

Correct nozzle size

Repair kit number

Standard fuel quantities

ID coding procedure


Just send the injector number or picture.
Here is a step-by-step guide for Toyota Hilux Vigo 2KD-FTV Common Rail Injector repair.
This engine uses Denso common-rail injectors, so accuracy and cleanliness are very important.


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✅ 2KD Common Rail Injector Repair / Service Guide

1. Tools & Materials Needed

17mm injector pipe spanner

12mm, 14mm socket set

Torque wrench

Diesel cleaner / injector cleaning fluid

Ultrasonic cleaner (optional but best)

Injector puller (if stuck)

New copper washers

New O-rings (if required)

Clean bench + lint-free cloth

Denso injector shim kit (for calibration)



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2. Removal of Injector

Step-By-Step

1. Disconnect battery


2. Remove engine cover


3. Remove injector pipes

Use 17mm spanner

Keep pipes clean—dust is dangerous for common rail.



4. Remove electrical connector


5. Remove return line (14mm banjo bolt)


6. Unscrew injector clamp (12mm bolt)


7. Pull injector out

If stuck, use injector puller

Do NOT twist too hard.





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3. Injector Disassembly (For Cleaning)

⚠️ Work in a clean place – smallest dirt will damage nozzle.

1. Open nozzle nut


2. Remove:

Nozzle

Needle

Valve plate

Solenoid body



3. Clean all parts in diesel or cleaning fluid


4. Use small brush → remove carbon


5. Use ultrasonic cleaner for best results


6. Inspect:

Needle movement free?

Nozzle holes open?

Valve plate not worn?



7. Replace:

Nozzle (if holes are worn)

Copper washer

O-ring





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4. Nozzle & Valve Set

For Vigo 2KD Denso injectors:

Standard Nozzle Codes

DLLA 145P870

DLLA 145P1058 (some models)


Setting Pressure

2KD injector pilot pressure isn’t set manually —
It is controlled electronically, so you only adjust shim thickness for idle balance.


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5. Re-assembly

1. Install nozzle + needle


2. Install valve plate & shim


3. Torque Nozzle Nut:
👉 55–60 Nm


4. Torque Solenoid Nut:
👉 10–12 Nm


5. Fit new copper washer


6. Make sure injector tip is clean and pointed straight.




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6. Install Injector Back Into Engine

1. Clean injector seat


2. Install new copper washer


3. Insert injector


4. Tighten clamp bolt:
👉 22–25 Nm


5. Install return line


6. Install injector pipes:
👉 30–35 Nm


7. Connect wiring