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Fuel Injector (For Direct Injection), Intake Manifold: Installation

  1. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the clean area shown in the illustration. Using a piece of cloth, clean carbon deposits from the injector and its grooves.
      NOTE:
      • Do not clean the tip of the injector.
      • Do not use a wire brush to clean the injector.
      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
        Fig 1: Identifying Seal Area Of Fuel Injector Seal
        G04947911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply engine oil to the injector contact surface of SST (guide). Then attach SST (guide) to the injector with the tapered inner portion facing the tip of the injector, as shown in the illustration.

      SST 09260-39015 (09268-03020) 

      Fig 2: Attaching SST To Injector With Tapered Inner Portion Facing Tip Of Injector
      G04947912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new injector seal to SST (holder).

      SST 09260-39015 (09268-03010) 

      NOTE: Be careful not to install the injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.
      Fig 3: Installing Injector Seal To SST (Holder)
      G04947913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install SST (holder with injector seal) to the tip of the injector. Slide the seal downward into the injector groove (injector connector side) with your fingers, as shown in the illustration.

      SST 09260-39015 (09268-03010, 09268-03020) 

      HINT:

      Check that the seal covers the circumference of the injector groove as shown in the illustration.

      Fig 4: Installing SST (Holder With Injector Seal) To Tip Of Injector
      G04947914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST (holder), gently press downward on the injector seal (injector connector side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.

      SST 09260-39015 (09268-03010, 09268-03020) 

      NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

      HINT:

      • When using SST (guide) to settle the seal into the groove, SST (guide) only needs to be slid upward to the position labeled A in the illustration.
      • After using SST (guide) to settle the seal into the groove, return SST (guide) to its position labeled B in the illustration.
        Fig 5: Sliding Seal Downward Into Injector Groove (Injector Connector Side)
        G04947915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install a new injector seal to the injector groove (injector tip side) as shown in the illustration.
      Fig 6: Installing Injector Seal To Injector Groove (Injector Tip Side)
      G04947916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check that the seal covers the circumference of the injector groove as shown in the illustration.

      SST 09260-39015 (09268-03010, 09268-03020) 

      NOTE: Make sure that the seal does not slip into the welded groove of the injector shown in the illustration. If it does, replace it with a new one.
      Fig 7: Checking Seal Covers Circumference Of Injector Groove
      G04947917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.

      SST 09260-39015 (09268-03020) 

      NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

      HINT:

      • Set SST (guide) so that its bottom surface and seal are flush.
      • If it is difficult to slide SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.
        Fig 8: Aligning Injector Contact Surface Of SST (Guide) With Seal
        G04947918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using SST (holder), gently press downward on the injector seal (injector tip side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.

      SST 09260-39015 (09268-03010, 09268-03020) 

      NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.
      Fig 9: Sliding SST (Guide) Towards Injector Tip
      G04947919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.

      SST 09260-39015 (09268-03020) 

      NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.

      HINT:

      • Set SST (guide) so that its bottom surface and the seal's bottom surface are flush.
      • If it is difficult to slide SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.
        Fig 10: Sliding SST (Guide) Towards Tip Of Injector
        G04947920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. After installing the seals, check that the seal is not scratched, deformed or protruding from the injector groove.
      NOTE: If the seal is scratched, deformed or protruding from the groove, replace it with a new one.
      Fig 11: Identifying Correct And Incorrect Position Of Injector Seal
      G04947921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL INJECTOR ASSEMBLY 
    1. Install a new O-ring, new backup rings (No. 1, No. 2, No. 3) and new E-ring to the fuel injector as shown in the illustration.
      Fig 12: Identifying O-Ring, Backup Rings And E-Ring To Fuel Injector
      G04947922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that the backup rings and O-ring are installed in the correct order.
      • Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
    2. Install the injector nozzle holder clamp.
    3. Apply gasoline to the O-ring. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.
      NOTE:
      • Make sure that there is no gap between the delivery pipe and clamp.
      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
      • Insert the injector straight into the delivery pipe without tilting it.
        Fig 13: Locating Injector Nozzle Holder Clamp
        G04947923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 FUEL DELIVERY PIPE 
    1. Install a new injector vibration insulator to the cylinder head.
    2. Apply lubricant to the installation hole of the injector.
    3. Insert the stud bolt into the fuel delivery pipe until the bolt's threads protrude enough so that a nut can be attached.
      NOTE:
      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        Fig 14: Identifying Stud Bolt Into Delivery Pipe
        G05286965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 15: Locating Fuel Delivery Pipe, Bolts And Nuts
      G05286964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 3 connectors, 2 clamps and fuel pressure sensor clamp.
  4. INSTALL NO. 2 FUEL DELIVERY PIPE 
    1. Install new injector vibration insulators to the cylinder head.
    2. Apply lubricant to the installation holes of the injectors.
    3. Insert the stud bolt into the delivery pipe until the bolts's threads protrude enough so that a nut can be attached.
      NOTE:
      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        Fig 16: Inserting Stud Bolt Into Delivery Pipe
        G05286965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 17: Locating Fuel Delivery Pipe, Nuts And Bolts
      G05286966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 3 connectors and 3 clamps.
  5. INSTALL NO. 3 FUEL PIPE 
    1. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown in the illustration.
      Fig 18: Identifying O-Ring, Backup Rings And E-Ring To Fuel Injector
      G05286967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that the backup rings and O-ring are installed in the correct order.
      • Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
      • Check that the fuel pipe installation end is not contaminated with foreign matter and is not damaged.
    2. Apply gasoline to the O-ring.
    3. Press the fuel pipe and delivery pipe together by hand until there is no gap between them. Then install the No. 3 fuel pipe with the 4 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE: Do not install the No. 3 fuel pipe at an angle.
      Fig 19: Pressing Fuel Pipe And Delivery Pipe
      G05286968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 FUEL PIPE 
    1. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown in the illustration.
      Fig 20: Identifying O-Ring, Backup Rings And E-Ring To Fuel Injector
      G05286967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that the backup rings and O-ring are installed in the correct order.
      • Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
      • Check that the No. 3 fuel pipe installation end is not contaminated with foreign matter and is not damaged.
    2. Apply gasoline to the O-ring and connect the fuel pipe to the delivery pipe.
      NOTE:
      • Do not install the No. 2 fuel pipe at an angle.
      • Do not install the bolt at this time.
      Fig 21: Identifying Fuel Pipe To Delivery Pipe
      G05286939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL PUMP ASSEMBLY (See  REMOVAL   ) 
  8. CONNECT NO. 2 FUEL PIPE (See  INSTALLATION   ) 
  9. INSTALL NO. 1 FUEL PIPE 
    1. Install the fuel pipe with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Connect the 2 fuel hoses.
      Fig 22: Identifying Fuel Pipe With Bolts
      G05286938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the No. 3 fuel hose to the No. 1 fuel pipe.
      Fig 23: Locating Fuel Hose And Clamp
      G05286937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FUEL PRESSURE PULSATION DAMPER 
    1. Install a new gasket and the fuel pulsation damper to the fuel pump.

      Torque: 35 N*m (367 kgf*cm, 26 ft.*lbf) for use with SST 

      40 N*m (408 kgf*cm, 30 ft.*lbf) for use without SST 

      SST 09612-24014 (09617-24011) 

      HINT:

      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
      • Make sure SST and wrench are connected in a straight line.
        Fig 24: Installing Fuel Pressure Pulsation Damper
        G05303189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL WATER HOSE JOINT 
    1. Install the water hose joint with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 25: Identifying Water Hose Joint With Bolt
      G05286936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL INTAKE MANIFOLD 
    1. Install a new gasket and the intake manifold with the 4 bolts and 4 nuts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 26: Locating Intake Manifold, Bolts And Nuts
      G05286935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 4 connectors.
      Fig 27: Locating Connectors
      G05286934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push in the fuel tube connector to the delivery pipe sub-assembly and push up the retainer to engage the claws.
      NOTE:
      • Check for damage or foreign objects on the connected part.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
        Fig 28: Pushing Fuel Tube Connector To Delivery Pipe Sub-Assembly
        G05303193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. After connecting the fuel tube, align the paint marks on the delivery pipe.
      Fig 29: Identifying Paint Marks On Delivery Pipe
      G05303194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL INTAKE AIR SURGE TANK (See  INSTALLATION   ) 
  14. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY  (See INSPECTION )
  15. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  (See INSTALLATION )
  16. CONNECT NO. 2 VENTILATION HOSE  (See INSTALLATION )
  17. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  20. INSTALL FRONT FENDER TO COWL SIDE SEAL LH  (See INSTALLATION )
  21. INSTALL FRONT FENDER TO COWL SIDE SEAL RH  (See INSTALLATION )
  22. INSTALL FRONT UPPER FENDER PROTECTOR LH  (See INSTALLATION )
  23. INSTALL FRONT UPPER FENDER PROTECTOR RH  (See INSTALLATION )
  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  25. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  26. ADD ENGINE COOLANT  (See REPLACEMENT )
  27. CHECK FOR COOLANT LEAKAGE  (See COOLING SYSTEM )
  28. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION   ) 
  29. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  30. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  31. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  32. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  33. CHECK FUNCTION OF THROTTLE BODY WITH MOTOR ASSEMBLY  (See ON-VEHICLE INSPECTION )
  34. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION (2006/02-2006/07) ).
      NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
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