Toyota Motor Europe

Bourgetlaan 60
1140 Brussels
Belgium

Disclaimers
1. Use of Technical Information
The technical information published on this website is intended and made
available only to users who have the necessary professional and technical skills,
knowledge and qualifications, as well as the necessary equipment and tools.
Specific repair or maintenance operations must be performed with the appropriate
specified equipment and tools, and replacement parts or components. Any repair
or maintenance operation undertaken by any user of this website on the basis of,
as a result of or in connection with the technical information published on this
website is performed under the sole responsibility of such user, and Toyota Motor
Europe NV/SA, any of its affiliated companies and/or any of its national
distributors cannot be held liable for any bodily injury, damage to property, loss,
expenses or any other damage, or any infringement to any laws or regulations, as a
result of any such repair or maintenance operation.
2. Warranty information contained within these documents
Any information which specifically relates to the terms and conditions of any
specific warranty action undertaken by Toyota Motor Europe NV/SA, any of its
affiliated companies and/or any of its national distributors, and which is included
in any document published on this website, does not constitute technical
information. Such information relates to past warranty actions undertaken by
Toyota Motor Europe NV/SA, any of its affiliated companies and/or any of its
national distributors, and, as a consequence, neither Toyota Motor Europe NV/SA
nor any of its affiliated companies or any of its national distributors are bound by
such warranty actions, or any term and condition thereof. Under no circumstances
shall such information constitute any undertaking, commitment or promise by
Toyota Motor Europe NV/SA, any of its affiliated companies and/or any of its
national distributors to apply, extend or renew such warranty action.
3. Upgrade or repair entitlement
The fact that a piece of technical information which relates to a specific upgrade
or repair work for any specific range of vehicles has been published on this
website, and that the vehicle belonging or used by a user of this website falls
within such range, does not, as such, mean that the user's vehicle effectively needs
to be upgraded or repaired or that they would be entitled to such upgrade or repair,
whether against payment or under any warranty action.

Technical Service Bulletin

04/10/2010

Subject:

SST Injector removal and bore cleaning.

Models:
EG-0114T-1010-EN

All models
Model codes:

Revised
This TSB EG-0014T-1010-## has been revised and is
replaced with EG-0094T-1112-##.

ENGINE

NUJ10, WNB10, NLP10, NLP20, NLP22, NLP90, NDE120,

NDE150, ADE150, ADE151, CDE120, AUR10, AUR20, AUR21,
CDT220, CDT250, ADT250, ADT251, ADT270, ADT271,
CLM20, KDJ90, KDJ95, KDJ120, KDJ125, KDJ150, KDJ155,
NLP110, NLP115, CLA20, CLA21, ALA30, ALA35, CLR30,
VDJ200, KDY261, KDY221, KDY230, KDY231, KDY250,
KDY251, KDY260, KDY261, KDH200, KDH201, KDH202,
KDH203, KDH212, KDH220, KDH221, KDH222, KDH223,
KLH12, KLH18, KLH22, KLH28, KUN10, KUN15, KUN16,
KUN25, KUN26, KUN35, KUN36, KDN145, KDN150, KDN165,
KDN170, KDN190.

5 pages

INTRODUCTION
This Technical Service Bulletin is to inform you of a new Special Service Tool.
This tool is applicable for all current direct injected Diesel engines.

DESCRIPTION OF PHENOMENON
Some technicians may face:
1. Difficulty to remove the injector from the cylinder head.
2. Difficulty to remove the injector seat from the cylinder head.
3. Difficulty to clean the injector bore.
4. Difficulty to clean the glow plug hole.

PARTS INFORMATION
Description

Current part number

Part name

Quantity

Main kit

PZ 485 903 9010

Injector bore cleaning kit

Spare parts

PZ 485 903 9015

Brush kit

Main kit

QUALITY
SERVICE

Spare parts

TOYOTA MOTOR EUROPE NV / SA

Page 2 of 5

EG-0114T-1010-EN

REPAIR PROCEDURE
Removing the Injector:

If an injector can not be removed easily, then it is possible to screw the handle
(p/n PZ 485 903 8438) for outer thread or handle (p/n PZ 485 903 8437) for
inner thread onto the diesel connection and through turning and pulling to
remove the injector from the bore.

In very severe cases the injector can be removed with the pivot adapter (p/n PZ
485 903 8440) and the slide hammer (p/n PZ 485 603 90750). Remove the Oring, slide the pivot adapter on the handle and return the O-ring in the groove
on the handle.
Screw the handle on the diesel connector and the slide hammer on the pivot
adapter. Knock the injector from the bore by simultaneously rotating and
striking.

Remove the dirt from in and around the Injector bore with compressed air or a vacuum cleaner.
Caution, wear safety goggles !
Tip: Good results can be obtained, by putting a funnel on the nozzle of the vacuum cleaner.

Cleaning the bore of the nozzle:

Remove the dirt and debris from the bore of the nozzle with the brass wire
brush (p/n PZ 485 904 9025).

Remove the dirt from in and around the Injector bore with compressed air or a vacuum cleaner.
Caution, wear safety goggles !

Placing the sealing plugs:

Place the sealing plug by means of the setting tool in the injector bore and
remove the setting tool (p/n PZ 485 603 90080).

QUALITY
SERVICE

TOYOTA MOTOR EUROPE NV / SA

Page 3 of 5

EG-0114T-1010-EN

Cleaning the injector shaft:

Measure the diameter of the removed injector and select the appropriate brass
brush:
18; p/n PZ 485 903 9132
19; p/n PZ 485 903 9131
21; p/n PZ 485 903 9129
24; p/n PZ 485 903 9128
Clamp the brass brush in the brush holder (p/n PZ 485 903 9033), put the
holder on the flexible-shaft (p/n PZ 485 903 9034) and place the shaft in the
drill. Guide the brush into the injector bore and clean the bore with low speed.

If the bore is very strongly polluted it is advisable, between brushing, to

occasionally clean the bore with compressed air or a vacuum cleaner.
Caution, wear safety goggles!
Repeat the operation until the injector bore is shiny clean.
Remove the dirt from in and around the injector bore with compressed air or a
vacuum cleaner. Caution, wear safety goggles !

If the copper seal still sticks in the injector shaft:

Remove the sealing plugs by means of the setting tool.

The knurled actuator of the sealing ring extractor must be freely movable and
should have some play from the knurled pipe.

Get a new sealing ring and place it on the extraction claw in order to adjust the
grip depth. The length of the claw can be changed by turning. The claw is
optimally adjusted when the collar protrudes minimally over the sealing ring. If
the collar protrudes too much, the extractor will jam in the bore of the nozzle
and can not grip the sealing ring. There also is a risk of damaging the cylinder
head. If the claw is not adjusted enough, then the extractor will not grip the
sealing ring.

QUALITY
SERVICE

TOYOTA MOTOR EUROPE NV / SA

EG-0114T-1010-EN

Page 4 of 5

After some usage, it can happen that the four claw elements get overstretched
and do not fit in the sealing ring anymore. This can be corrected by squeezing
them together with a pair of long-nosed pliers.

Place the sealing ring extractor (p/n PZ 485 6039070) in the bore with the slide
hammer (p/n PZ 485 903 90750) screwed on and knock, with caution, the claw
into the hole of the sealing ring.
Remove the slide hammer.

Grip the sealing ring by turning the knurled actuator and holding the knurled
pipe.

Screw the slide hammer on the sealing ring extractor and knock with caution
the copper seal out of the injector bore.

Remove the dirt from in and around the Injector bore with compressed air or a
vacuum cleaner.
Caution, wear safety goggles !

Place the sealing plug by means of the setting tool in the injector bore and
remove the setting tool.

QUALITY
SERVICE

TOYOTA MOTOR EUROPE NV / SA

Page 5 of 5

EG-0114T-1010-EN

Cleaning the seat of the injector:

Plug the brass end brush (p/n PZ 485 903 9011) onto the flexible shaft.
Slide the plastic guide (p/n PZ 485 903 9016) on the flexible shaft and
and brush.

Clamp the flexible-shaft in the drill and place the guide in the injector bore.
Guide the brush in the injector shaft and clean the sealing seat at low speed.
When cleaning the injection shaft, do not use too much force when
scrubbing or spin the brush at high speeds as this may damage the
sealing surface where the nozzle seat is installed. If the sealing surface is
damaged, a sealing problem may occur. Repeat the operation until the injector
bore is shiny clean.
Remove the dirt from in and around the Injector shaft with compressed air or a
vacuum cleaner.
Caution, wear safety goggles !

Remove the sealing plugs by means of the setting tool.

Guide the brush again in the injector bore and repeat shortly the cleaning of the
sealing seats.

Remove the dirt from in and around the Injector bore with compressed air or a
vacuum cleaner.
Caution, wear safety goggles !

Cleaning the glow plug shaft:

This brush is an additional feature and is added to the kit in case of glow plug
replacement.
Remove the glow plugs. Clean the glow plug bore with stepped brass wire
brush (p/n PZ 485 904 9026).
Remove the dirt from in and around the glow plug bore with compressed air or
a vacuum cleaner.
Caution, wear safety goggles !

Please see Techdoc1 for translated versions of the user manual:

http://www.toyota-tech.eu Repair Diesel injector seat cleaning kit
http://www.lexus-tech.eu Repair Diesel injector seat cleaning kit

QUALITY
SERVICE

TOYOTA MOTOR EUROPE NV / SA