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 tip of the injector is struck, replace it with a new one.
     Fig 1: Identifying 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 Fuel Injector Seal (Tapered Inner Portion)

   Courtesy 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

   Courtesy 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 (09268-03020, 09268-03010) 

   HINT:

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

   Fig 4: Identifying Injector Seal To SST

   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.

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

   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: Pressing Injector Seal

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install a new injector seal to SST (holder)

   SST (Guide) Injector Seal 

   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

   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 (09268-03020, 09268-03010) 

   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 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: Identifying Injector Seal And SST

     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 (09268-03020, 09268-03010) 

   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: Pressing 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.

    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: Identifying Injector Seal With SST

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. After installing the seals, check that the seals are not scratched, deformed or protruding from the groove.

    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 and No. 3) and a new E-ring to the fuel injector as shown in the illustration
   Fig 11: Identifying Seal Correct And Incorrect Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 12: Identifying Fuel Injector Parts

   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. 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: Locating Injector Nozzle Clamp

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   NOTE:

   • If an injector is dropped or the tip of the injector is 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 Cylinder Head Bolts

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the No. 3 fuel hose and fuel relief valve connector
Fig 16: Locating No. 3 Fuel Hose And Fuel Relief Valve Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   NOTE:

   • If an injector is dropped or the tip of the injector is 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 17: Locating Cylinder Head Bolts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the 4 injector connectors.
   Fig 18: Locating Injector Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the fuel pressure sensor connector.
   Fig 19: Locating Fuel Pressure Sensor Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the fuel pipe.
2. Using a 19 mm union nut wrench, tighten the fuel pipe in the order shown in the illustration

   Torque: without union nut wrench 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   with union nut wrench 

   27 N*m (275 kgf*cm, 20 ft.*lbf) 

   NOTE: After installing the fuel pipe, check that the fuel pipe protector contacts with the separator case.

   HINT

   • Use a torque wrench with a fulcrum length of 30 cm (11 8 in.).
   • Make sure use the union nut wrench and torque wrench are connected in a straight line.
     Fig 20: Tightening Fuel Pipe

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring, new backup rings (No. 1 and No. 2) and a new E-ring to the fuel pipe as shown in the illustration.
   Fig 23: Identifying No. 1 Engine Cover Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 24: Identifying O-Ring Incorrect And Correct

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check that there is no foreign matter or damaged areas in the fuel pipe'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
   Fig 25: Locating No. 3 Fuel Pipe To Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the No. 3 fuel pipe to the fuel pump.
   NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
   Fig 26: Identifying No. 3 Fuel Pipe To Fuel Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 2 bolts in several passes

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

5. Using a 19 mm union nut wrench, tighten the union nut.

   Torque: without union nut wrench 

   30 N*m (306 kgf*cm, 22 ft.*lbf) 

   with union nut wrench 

   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 (11.8 in)
   • Make sure use the union nut wrench and torque wrench are connected in a straight line
   Fig 27: Identifying Fulcrum Length
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the fuel pump connector

HINT:

The installation procedures are the same as for the No. 3 fuel pipe.

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