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

  1. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the injector area shown in the illustration. Using a piece of cloth, clean carbon deposits from the injector and its grooves.
      Fig 1: Identifying Clean Area
      G04056442Courtesy 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, as shown in the illustration.
      Fig 2: Identifying Tapered Inner Portion
      G04056443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09260-39015 (09268-03020) 

    3. Install a new injector seal to SST (holder).
      Fig 3: Installing Injector Seal To SST (Holder)
      G04056444Courtesy 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, as shown in the illustration.
      Fig 4: Sliding Seal Downward Into Injector Groove (Injector Connector Side)
      G04056445Courtesy 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 the illustration.

    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: Pressing Downward On Injector Seal (Injector Connector Side) Using SST (Holder)
      G04056446Courtesy 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 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.
    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)
      G04056447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    7. Check that the seal covers the circumference of the injector groove as shown in the illustration.
      Fig 7: Checking Seal Covers Circumference Of Injector Groove
      G04056448Courtesy 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 the illustration. 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) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.
      Fig 8: Sliding SST (Guide) Towards Tip Of Injector
      G04056449Courtesy 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
      G04056450Courtesy 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 the illustration, 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
      G04056451Courtesy 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 And Incorrect Seal
      G04056452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: If the seal is scratched, deformed or protruding from the groove, replace it with a new one.
  2. INSTALL FUEL INJECTOR 
    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: Installing O-Ring, Backup Rings (No.1, No.2, No.3) And E-Ring To Fuel Injector
      G04056453Courtesy 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.
      Fig 13: Identifying Nozzle Holder Clamp
      G04056454Courtesy 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.
  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 screw threads protrude enough so that a nut can be attached.
      Fig 14: Inserting Stud Bolt Into Fuel Delivery Pipe
      G04056455Courtesy 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 the illustration.

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

      Fig 15: Identifying Bolts And Nuts Tightening Sequence
      G04056456Courtesy 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 screw threads protrude enough so that a nut can be attached.
      Fig 16: Inserting Stud Bolt Into Delivery Pipe
      G04056457Courtesy 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 the illustration.

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

    5. Connect the 3 connectors and 3 clamps.
      Fig 17: Identifying Bolts And Nuts Tightening Sequence
      G04056458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 3 FUEL PIPE 
    1. Install a new O-ring, new backup rings (No. 1, No. 2) and new E-ring to the fuel injector as shown in the illustration.
      Fig 18: Installing O-Ring, Backup Rings (No.1, No.2) And E-Ring To Fuel Injector
      G04056459Courtesy 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: Identifying No.3 Fuel Pipe With 4 Bolts
      G04056460Courtesy 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: Installing O-Ring, Backup Rings (No.1 And No.2) And E-Ring To Fuel Injector
      G04056461Courtesy 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.
  7. INSTALL FUEL PUMP ASSEMBLY (See  REMOVAL   ) 
  8. CONNECT NO. 2 FUEL PIPE (See  INSTALLATION   ) 
    Fig 21: Identifying No.2 Fuel Pipe
    G04056462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 Hoses
      G04056463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the No. 3 fuel hose to the No. 1 fuel pipe.
      Fig 23: Connecting No.3 Fuel Hose To No.1 Fuel Pipe
      G04056464Courtesy 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.
      Fig 24: Identifying Fuel Pressure Pulsation Damper
      G04056465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 40 N*m (408 kgf*cm, 30 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 ).

  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
      G04056466Courtesy 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.
      Fig 26: Identifying Intake Manifold
      G04056467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the 4 connectors.
      Fig 27: Identifying Connectors
      G04056468Courtesy 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.
      Fig 28: Pushing Fuel Tube Connector To Delivery Pipe Sub-Assembly
      G04056469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    4. After connecting the fuel tube, align the paint marks on the delivery pipe.
      Fig 29: Identifying Paint Marks
      G04056470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL INTAKE AIR SURGE TANK (See  INSTALLATION   ) 
  14. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY (See  INSTALLATION  ) 
  15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See  INSTALLATION  ) 
  16. CONNECT NO. 2 VENTILATION HOSE (See  INSTALLATION  ) 
  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See  INSTALLATION  ) 
  18. ADD ENGINE COOLANT (See  COOLANT  ) 
  19. CHECK FOR COOLANT LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  20. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION   ) 
  21. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See  INSTALLATION  ) 
  22. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See  INSTALLATION  ) 
  23. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See  INSTALLATION  ) 
  24. INSTALL FRONT WIPER ARM HEAD CAP (See  INSTALLATION  ) 
  25. INSTALL ROOF DRIP SIDE FINISH MOULDING LH 
  26. INSTALL ROOF DRIP SIDE FINISH MOULDING RH 
  27. INSTALL FRONT UPPER FENDER PROTECTOR LH (See  INSTALLATION  ) 
  28. INSTALL FRONT UPPER FENDER PROTECTOR RH 

    HINT:

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

  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 (See  ON-VEHICLE INSPECTION  ) 
  34. PERFORM INITIALIZATION 
    1. Perform initialization (See INITIALIZATION ).

      HINT:

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

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