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FUEL INJECTOR (for Direct Injection): 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 fuel injector assembly and its grooves.
      NOTE:
      • Do not clean the tip of the fuel injector assembly.
        Fig 1: Identifying Fuel Injector Clean Area
        G04947911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not use a wire brush to clean the fuel injector assembly.
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
    2. Apply engine oil to the fuel injector assembly contact surface of SST (guide). Then attach SST (guide) to the fuel injector assembly with the tapered inner portion facing the tip of the fuel injector assembly as shown in the illustration

      SST 09260-39015 (09268-03020) 

      Fig 2: Identifying Fuel Injector Assembly With Tapered Inner Portion
      G04947912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new fuel injector seal to SST (holder).

      SST 09260-39015 (09268-03010) 

      NOTE: Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.
      Fig 3: Identifying Fuel Injector Seal To SST (Holder)
      G05749974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install SST (holder with fuel injector seal) to the tip of the fuel injector assembly. Slide the seal downward into the fuel injector assembly groove (fuel injector assembly 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 fuel injector assembly groove as shown in the illustration.

      Fig 4: Sliding Seal Downward Into Fuel Injector Assembly Groove
      G04947914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST (holder), gently press downward on the fuel injector seal (fuel injector assembly connector side). Then slowly slide SST (guide) towards the fuel injector assembly tip to settle the seal into the fuel injector assembly groove

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

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

      HINT

      • When using SST (guide) to settle the fuel injector 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 fuel injector seal into the groove, return SST (guide) to its position labeled B in the illustration.
      Fig 5: Sliding SST (Guide) Towards Fuel Injector Assembly
      G05749976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install a new fuel injector seal to SST (holder).

      SST 09260-39015(09268-03010) 

      NOTE: Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal and correcting this problem is very complicated.
      Fig 6: Installing New Fuel Injector Seal To SST (Holder)
      G05749977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install SST (holder with fuel injector seal) to the tip of the fuel injector assembly Slide the seal downward into the fuel injector assembly 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 fuel injector assembly shown in the illustration. If it does, replace it with a new one.

      HINT:

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

      Fig 7: Sliding Seal Downward Into Fuel Injector Assembly Groove With Fingers
      G05749978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Slowly slide SST (guide) towards the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the fuel injector assembly groove.

      SST 09260-39015(09268-03020) 

      NOTE: Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector 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 fuel injector assembly little by little
      Fig 8: Sliding SST (Guide) Towards Tip Of Fuel Injector Assembly
      G05749979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using SST (holder), gently press downward on the injector fuel injector seal (fuel injector assembly tip side). Then slowly slide SST (guide) towards the fuel injector assembly tip to settle the fuel injector seal into the fuel injector assembly groove.

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

      NOTE: Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.
      Fig 9: Sliding SST (Guide) Towards Fuel Injector Assembly Tip
      G05749980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Slowly slide SST (guide) towards the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the fuel injector seal into the fuel injector assembly groove.

      SST 09260-39015 (09268-03020) 

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

      HINT:

      • Set SST (guide) so that its bottom surface and the fuel injector seal bottom surface are flush.
      • If it is difficult to slide SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little
      Fig 10: Sliding SST (Guide) Towards Fuel Injector Assembly Tip
      G05749981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. After installing the seals, check that the seals are not scratched, deformed or protruding from the fuel injector assembly grooves.
      NOTE: If any seal is scratched, deformed or protruding from the groove, replace it with a new one.
      Fig 11: Identifying Correct And Incorrect Position Of Seals
      G04947921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) 
    1. Install a new O-ring, new backup rings (No 1, No 2 and No 3) and a new E-ring to the fuel injector assembly as shown in the illustration.
      Fig 12: Identifying O-Ring, E-Ring And Backup Rings
      G04947922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector 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 or damaged.
    2. Install the nozzle holder clamp.
      1. Apply engine oil 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 Nozzle Holder Clamp
        G04947923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 FUEL DELIVERY PIPE (for Direct Injection) 
    1. Install 4 new injector vibration insulators to the cylinder head
    2. Apply lubricant to the installation surfaces of the fuel injector seal and fuel injector holes
      Fig 14: Locating Injector Vibration Insulators
      G05749964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No. 2 fuel delivery pipe (with fuel injector assembly) to the cylinder head with the 5 bolts.

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

      NOTE:
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the cylinder head.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        • Fig 15: Locating Fuel Delivery Pipe Bolts
        G04947904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 4 injector connectors.
      5. Fig 16: Locating Injector Connectors
      G05749962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL DELIVERY PIPE (for Direct Injection) 
    1. Install 4 new injector vibration insulators to the cylinder head.
    2. Apply lubricant to the installation surface of the fuel injector seal and fuel injector holes.
      Fig 17: Locating Injector Vibration Insulators
      G05749967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the delivery pipe (with fuel injector assembly) to the cylinder head with the 5 bolts

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

      NOTE:
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the cylinder head.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        • Fig 18: Locating Delivery Pipe Bolts
        G04947907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 4 injector connectors.
      5. Fig 19: Locating Injector Connectors
      G05749965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL SEPARATOR CASE 
    1. Install separator case to the cylinder head with the 4 bolts.

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

      Fig 20: Locating Separator Case Bolts
      G04943090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the fuel pressure sensor connector.
      3. Fig 21: Locating Fuel Pressure Sensor Connector
      G04947902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Temporarily install the No. 4 fuel pipe sub-assembly
    2. Using a 19 mm union nut wrench, tighten the No 4 fuel pipe sub-assembly in the order shown in the illustration.

      Torque: without a union nut wrench 

      30 N*m (306 kgf*cm, 22 ft.*lbf) 

      with a union nut wrench 

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

      NOTE: After installing the No. 4 fuel pipe sub-assembly, check that the No. 4 fuel pipe sub-assembly protector contacts the separator case.

      HINT:

      • Use a torque wrench with a fulcrum length of 30 cm (11.8 in)
      • Make sure that the union nut wrench and torque wrench are connected in a straight line.
        • Fig 22: Identifying Fuel Pipe Protector And Separator Case
        G05749993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH 
    1. Install the No 2 engine cover sub-assembly LH.
      2. Fig 23: Locating Engine Cover LH
      G05749958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Install the No. 1 engine cover sub-assembly.
    Fig 24: Identifying Engine Cover
    G05749957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY  (See INSTALLATION )
  10. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY  (See INSTALLATION )
  11. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (for Direct Injection) 
    1. Install the 2 fuel pressure pulsation damper assemblies and No. 1 fuel pipe sub-assembly (See INSTALLATION )
  12. INSTALL NO. 3 COVER SUB-ASSEMBLY  (See INSTALLATION )
  13. INSTALL ENGINE WIRE  (See INSTALLATION )
  14. CONNECT NO. 1 FUEL HOSE  (See INSTALLATION )
  15. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    1. Install the intake air surge tank assembly (See INSTALLATION ).
  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  17. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
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