FuelPartsDB · WORKSHOP TECHNICAL SERVICE

DOC REF: SOP-CR-INJ-01

WORKSHOP INSTALLATION JOB SHEET & SOP

DENSO 095000-6640Denso 095000-6640 Injector | Toyota 23670-0L050 2KD-FTV · Euro 34

Technician / Installer:

Date / Odometer:

Vehicle Reg / VIN:

Quality Sign-off:

CRITICAL INSTALLATION SPECIFICATIONS & TORQUES

Torques (Hold-down):30 N·m

Torques (Tightening):32 N·m

Copper washer:Renew the sealing washer on every installation. 1.50 mm standard; step up to 1.70 mm after light seat reaming, 2.00 mm after heavy seat refinishing.

IMA / ECU coding:Required after replacement

MANDATORY INSTALLATION CHECKLIST

[ ]Bore cleaned to bare metal using nylon/brass reaming brush & vacuumed (zero debris / no steel wire)
[ ]New copper sealing washer fitted with correct thickness (do not reuse old washer)
[ ]High-temperature ceramic paste applied to injector body shaft (never coat the nozzle tip)
[ ]Hold-down clamp bolt tightened in stage torque/angle sequence as specified
[ ]Fuel rail high-pressure line union torqued without tension or cross-threading
[ ]IMA / QR calibration code entered into diagnostic tool (Lexia/KTS/VCDS) for cylinder balancing
[ ]Low-pressure air bleed performed, engine idling leak-off test verified leak-free

DENSO

095000-6640

View Specs

SolenoidDenso Common Rail System (CRS G2 / HP3 Series)Euro 34

Denso 095000-6640 Injector | Toyota 23670-0L050 2KD-FTV

Reference data for Bosch 095000-6640 common rail injector · OEM 23670-0L050, 23670-09330, 23670-09070, 23670-30220, 23670-39185, 23670-39275, DCRI106640 · Application Toyota 2KD-FTV (2.5L D-4D DOHC 16V)

Engine Platform:Toyota 2KD-FTV (2.5L D-4D DOHC 16V) →

OE REFERENCE23670-0L050, 23670-09330, 23670-09070, 23670-30220, 23670-39185, 23670-39275, DCRI106640

CONTROL VALVEPlate

NOZZLEDLLA155P863

RAIL PRESSURE1600 bar

EMISSIONEuro 3 / Euro 4

WARRANTY12 Months

Compatible Injectors

OEM Ref

OE Nozzle

Vehicle & Engine Fitment

Vehicle	Engine	Years
Toyota Hilux 2.5 D-4D Pickup	Toyota 2KD-FTV (2.5L D-4D DOHC 16V)	2004-2016
Toyota HiAce 2.5 D-4D Van	Toyota 2KD-FTV (2.5L D-4D DOHC 16V)	2004-2016
Toyota Fortuner 2.5 D-4D SUV	Toyota 2KD-FTV (2.5L D-4D DOHC 16V)	2005-2015
Toyota Innova 2.5 D-4D MPV	Toyota 2KD-FTV (2.5L D-4D DOHC 16V)	2004-2015

Technical Specifications

Specification	Value
INJECTOR TYPE	Common Rail Injector
SYSTEM PLATFORM	CRI
CONTROL VALVECore Spec
NOZZLE CODECore Spec
OPERATING PRESSURECore Spec

Diagnostic Trouble Codes & Fault Protocols

Common diagnostic trouble codes (DTCs) triggered when this common rail injector experiences wear, circuit faults, or calibration drift:

P0087Critical

Fuel Rail / System Pressure Too Low

Excessive internal backleak from worn control valve seats drops common rail pressure below target under engine load.

P0087 Guide →🧪 Backleak Calculator

P0201 - P0208High

Injector Circuit Malfunction / Open Circuit

Solenoid coil resistance drift (0.2-0.5 Ω) or piezo stack degradation triggers driver stage shutdown on affected cylinders.

P0201 Circuit Guide →

P0300 / P0301+High

Cylinder Misfire & Balancing Deviation

Carbon-clogged nozzle spray holes or missing IMA calibration causes uneven cylinder contribution. Recode ECM and verify washer seating.

P0300 Misfire Protocol →💻 IMA Coding Tool 📐 Washer Thickness

P0088High

Fuel Rail / System Pressure Too High

Spill line backpressure or stuck metering valve prevents rail depressurization, creating overpressure risks under load.

P0088 Guide →📊 Rail Pressure Converter

Browse all 61 Diesel Diagnostic Trouble Codes in our Workshop Hub ->

WORKSHOP PROTOCOLS

Technical Diagnostic & Service Protocols

Authoritative field procedures, diagnostic testing thresholds, and service SOPs for this assembly.

Workshop Diagnostic Protocol

Common Rail Injector Back-Leak Testing Guide

Common rail injector backleak test protocol. Graduated cylinder setup, warm idle & cranking limits in mL/min, control valve wear & P0087 diagnosis.

Read Technical Protocol

COMMON RAIL DIESEL WORKSHOP SOP

Stuck Injector Removal & Carbon Cleaning SOP | FuelPartsDB

Comprehensive workshop SOP for stuck diesel injector removal, pneumatic vibro-puller extraction, carbon solvent softening, and seat reaming without damage.

Read Technical Protocol

ASSEMBLY & INSTALLATION PROTOCOL

Diesel Injector Torque Specs & TTY Angles Guide

Common rail diesel injector hold-down bolt torque specs, TTY angles & pipe unions. Covers Bosch, Detroit DD13, Cummins & VAG 2.0 TDI workshop data in Nm.

Read Technical Protocol