FUEL INJECTOR (for Direct Injection): Installation

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: Applying Engine Conditioner To Clean Area

     Courtesy 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: Identifying SST (Guide)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new injector seal to SST (holder).
   Fig 3: Installing 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, 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 To Tip Of Injector

   Courtesy 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.
   Fig 5: Installing Injector Seal

   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 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 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 6: Installing Injector Seal To SST (Holder)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install SST (holder with injector seal) to the tip of the injector. Slide the seal downward into the injector groove (injector tip side) with your fingers, 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.

   HINT:

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

   Fig 7: Installing SST To Tip Of Injector

   Courtesy 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: Sliding SST (Guide) Towards Tip Of Injector

     Courtesy 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: Installing Injector Seal

   Courtesy 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.
    Fig 10: Identifying Injector Seal And SST (Guide)

    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 it is difficult to slide 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 seals are not scratched, deformed or protruding from the injector grooves.
    NOTE: If the seal is scratched, deformed or protruding from the groove, replace it with a new one.
    Fig 11: Identifying Correct And Incorrect Installation Of Injector Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring, backup rings (No. 1, No. 2 and No. 3) and E-ring to the fuel injector as shown in the illustration.
   Fig 12: Identifying O-Ring, Backup Rings And E-Ring Of 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 13.
   • 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.
   1. 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: Identifying Injector Nozzle Holder Clamps

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 4 new injector vibration insulators to the cylinder head.
2. Apply lubricant to the installation injector seal and holes of the injectors.
3. Install the delivery pipe (with injector) to the intake manifold with the 5 bolts.

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

   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 cylinder head.
   • When inserting the fuel delivery pipe, push it in evenly without tilting it.
   Fig 14: Locating Delivery Pipe Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the 4 connectors.
   Fig 15: Locating Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the fuel pressure sensor connector.
   Fig 16: Locating Fuel Pressure Sensor Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 4 new injector vibration insulators to the cylinder head.
2. Apply lubricant to the installation injector seal and holes of the injectors.
3. Install the delivery pipe (with injector) to the intake manifold with the 5 bolts.
   Fig 17: Locating Delivery Pipe Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 2\ N*m (214 kgf*cm, 15 ft.*lbf) 

   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 cylinder head.
   • When inserting the fuel delivery pipe, push it in evenly without tilting it.
4. Connect the 4 connectors.
   Fig 18: Locating Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the No. 3 fuel hose.
   Fig 19: Identifying Fuel Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the ventilation hose to the ventilation valve.
   Fig 20: Locating Ventilation Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the fuel pipe.
   Fig 21: Tightening Fuel Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, tighten the fuel pipe in the order shown in the illustration.

   SST 09023-12901 

   Torque: 

   without SST 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   with SST 27 N*m (275 kgf*cm, 20 ft.*lbf) 

   NOTE: After installing the fuel pipe, check that there is contiguous the fuel pipe protector and separator case.

   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.

1. Install the No. 1, No. 2 and LH No. 2 engine covers.
   Fig 22: Identifying Engine Cover Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring, backup rings (No. 1 and No. 2) and E-ring to the fuel injector as shown in the illustration.
   Fig 23: Identifying O-Ring, Backup Rings And E-Ring Of 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 the illustration.
   • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
2. Temporarily install the No. 3 fuel pipe to the delivery pipe with the 2 bolts.

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

   Fig 24: Locating Fuel Pipe Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the No. 3 fuel pipe sub-assembly to the fuel pump.
   Fig 25: Locating Fuel Pipe Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
4. Install the No. 3 fuel pipe to the delivery pipe with the 2 bolts and tighten them in several passes.

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

5. Using SST, tighten the union nut.

   SST 09023-12901 

   Torque: 

   without SST 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   with SST 27 N*m (275 kgf*cm, 20 ft.*lbf) 

   NOTE: There must be absolutely no free play in the union on the fuel pump side. If the union on the fuel pump side has free play, replace the fuel pump.

   HINT:

   • Use a torque wrench with a fulcrum length of 30 cm (11.81 in).
     Fig 26: Identifying Fulcrum Length Of Torque Wrench

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Make sure SST and wrench are connected in a straight line.
6. Connect the connector to the fuel pump.

HINT:

The installation procedures are the same as the No. 3 fuel pipe sub-assembly.

1. Install the fuel pressure pulsation damper assembly (see INSTALLATION  ).

1. Install the intake manifold (see INSTALLATION ).

1. Perform initialization (see PRECAUTION ).
   NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable to the negative (-) battery terminal.