Fuel Injector, Intake Manifold: Installation

1. Apply engine conditioner to the injector area shown in Fig 1. Using a piece of cloth, clean carbon deposits from the injector and its grooves.
   Fig 1: Identifying Injector Area For Applying Engine Conditioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.
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.
   Fig 2: Attaching SST To Injector With Tapered Inner Portion Facing Tip Of Injector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09260-39015 (09268-03020) 

3. Install a new injector seal to SST (holder).
   Fig 3: Installing New Injector Seal To SST (Holder)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.
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.
   Fig 4: Installing SST (Holder With Injector Seal) To Tip Of Injector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   HINT:

   Check that the seal covers the circumference of the injector groove as shown in Fig 4 .

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.
   Fig 5: Sliding SST (Guide) Towards Injector Tip To Settle Seal Into Injector Groove

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.
   • After using SST (guide) to settle the seal into the groove, return SST (guide) to its position labeled B.
6. Install a new injector seal to the injector groove (injector tip side).
   Fig 6: Installing New Injector Seal To Injector Groove (Injector Tip Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

7. Check that the seal covers the circumference of the injector groove.
   Fig 7: Checking That Seal Covers Circumference Of Injector Groove

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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 Fig 7. If it does, replace it with a new one.
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), hold the position for 5 seconds or more to fully align the seal into the injector groove.
   Fig 8: Aligning Injector Contact Surface Of SST (Guide) With Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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 there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.
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.
   Fig 9: Sliding SST (Guide) Towards Injector Tip To Settle Seal Into Injector Groove

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.
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 Fig 10, hold the position for 5 seconds or more to fully align the seal into the injector groove.
    Fig 10: Sliding SST (Guide) Towards Tip Of Injector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    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 there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.
11. After installing the seals, check that the seal is not scratched, deformed or protruding from the injector groove.
    Fig 11: Identifying Correct & Incorrect Position Of Injector Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If the seal is scratched, deformed or protruding from the groove, replace it with a new one.

1. Install a new O-ring, new backup rings (No. 1, No. 2, No. 3) and new E-ring to the fuel injector.
   Fig 12: Installing New O-Ring, New Backup Rings & New E-Ring To Fuel Injector

   Courtesy 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 Fig 12.
   • 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.
   Fig 13: Installing Injector Nozzle Holder Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

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 screw threads protrude enough so that a nut can be attached.
   Fig 14: Inserting Stud Bolt Into Fuel Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.
4. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in Fig 15 .
   Fig 15: Installing Fuel Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

5. Connect the 3 connectors and 2 clamps.

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 screw threads protrude enough so that a nut can be attached.
   Fig 16: Inserting Stud Bolt Into Fuel Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.
4. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in Fig 17 .
   Fig 17: Installing Fuel Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

5. Connect the 3 connectors and 3 clamps.

1. Install a new O-ring, new backup rings (No. 1, No. 2) and new E-ring to the fuel injector.
   Fig 18: Installing New O-Ring, New Backup Rings & New E-Ring To Fuel Injector

   Courtesy 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 Fig 18 .
   • 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.
   Fig 19: Installing No. 3 Fuel Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   NOTE: Do not install the No. 3 fuel pipe at an angle.

1. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector.
   Fig 20: Installing New O-Ring, New Backup Rings & New E-Ring To Fuel Injector

   Courtesy 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 Fig 20 .
   • 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.
   Fig 21: Connecting Fuel Pipe To Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Do not install the No.2 fuel pipe at an angle.
   • Do not install the bolt at this time.

1. Install the fuel pipe with the 2 bolts.
   Fig 22: Installing No. 1 Fuel Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Connect the 2 fuel hoses.

1. Using SST, install a new gasket and the fuel pulsation damper to the fuel pump.
   Fig 23: Installing Fuel Pressure Pulsation Damper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 40 N*m (408 kgf*cm, 28 ft.*lbf) 

   HINT:

   The torque shown above should be used for tightening without using SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST (See REPAIR INSTRUCTION ).

1. Connect the water hose joint with the bolt.
   Fig 24: Connecting Water Hose Joint

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install a new gasket and the intake manifold with the 4 bolts and 4 nuts.
   Fig 25: Installing Intake Manifold

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Connect the SCV position sensor connector.
3. Connect the DC motor connector for the SCV.

1. Install a new gasket to the intake air surge tank.
2. Using a 5 mm hexagon socket wrench, install the 6 bolts.
   Fig 26: Installing Intake Air Surge Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: Bolts except A 

   18 N*m (184 kgf*cm, 13 ft.*lbf) 

3. Install the bolt and 2 nuts to the intake air surge tank.

   Torque: Bolt A 

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

   16 N*m (163 kgf*cm, 12 ft.*lbf) 

4. Install the surge tank stay to the intake air surge tank.
   Fig 27: Installing Surge Tank Stay To Intake Air Surge Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

5. Connect the water hose joint with the bolt.
   Fig 28: Connecting Water Hose Joint

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

6. Connect the ventilation hose to the intake air surge tank.
   Fig 29: Connecting Ventilation Hose To Intake Air Surge Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the wire harness and hose to the intake air surge tank.
   Fig 30: Connecting Wire Harness & Hose To Intake Air Surge Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Connect the No. 1 vacuum switching valve assembly to the intake air surge tank.
   Fig 31: Connecting No. 1 Vacuum Switching Valve Assembly To Intake Air Surge Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

9. Connect the vacuum hose to the intake air surge tank.

1. Connect the cold start injector with the 2 bolts.
   Fig 32: Installing Cold Start Injector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Connect the cold start injector connector.

HINT:

Installation procedure of the RH side is the same as that of the LH side.

1. Perform initialization (See INITIALIZATION ).

   HINT:

   Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.