Fuel Injector, Intake Manifold: Installation: Installation

WARNING: This page is about a different car, the 2011 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.

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
  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, as shown in the illustration.
  
  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 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.
  
  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 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: Sliding Seal Downward Into Injector Groove (Injector Connector Side)
  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 the injector groove (injector tip side) as shown in the illustration.
  
  Fig 6: Installing Injector Seal To SST (Holder)
  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 as shown in the illustration.
  
  Fig 7: Checking 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 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: 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: Pressing Downward On Injector Seal (Injector Tip Side)
  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 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
  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 And 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.
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: Identifying New O-Ring, New Backup Rings, New E-Ring & 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. 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: Locating 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.
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
  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 the illustration.
  
  Fig 15: Identifying Fuel Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 26 N.m (265 kgf cm, 19 ft. lbf)
5. Connect the 3 connectors and 2 clamps.
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 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 the illustration.
  
  Fig 17: Identifying Fuel Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 26 N.m (265 kgf cm, 19 ft. lbf)
5. Connect the 3 connectors and 3 clamps.
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: Identifying 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 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.
  
  Fig 19: Identifying 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.
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: Identifying 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 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.
  
  Fig 21: Identifying No. 2 Fuel Pipe Sub-Assembly
  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.
INSTALL FUEL PUMP ASSEMBLY See step 1
CONNECT NO. 2 FUEL PIPE See step 2
INSTALL NO. 1 FUEL PIPE
1. Install the fuel pipe with the 2 bolts.
  
  Fig 22: Identifying 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.
INSTALL FUEL PRESSURE PULSATION DAMPER See step 1
CONNECT WATER HOSE JOINT
1. Connect the water hose joint with the bolt.
  
  Fig 23: Identifying Water Hose Joint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N.m (102 kgf cm, 7 ft. lbf)
INSTALL INTAKE MANIFOLD
1. Install a new gasket and the intake manifold with the 4 bolts and 4 nuts.
  
  Fig 24: Identifying 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.
INSTALL INTAKE AIR SURGE TANK
1. Install a new gasket to the intake air surge tank.
  
  Fig 25: Identifying Intake Air Surge Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 5 mm hexagon socket wrench, install the 6 bolts.
  Bolts except A
  
  Torque: 18 N.m (184 kgf cm, 13 ft. lbf)
3. Install the bolt and 2 nuts to the intake air surge tank.
  Bolt A
  
  Torque: 21 N.m (214 kgf cm, 15 ft. lbf)
  
  Nut
  
  Torque: 16 N.m (163 kgf cm, 12 ft. lbf)
4. Install the surge tank stay to the intake air surge tank.
  
  Fig 26: Identifying Surge Tank Stay
  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 27: Identifying 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 28: 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 29: View Of Wire Harness & Hose To Intake Air Surge Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Connect the purge VSV to the intake air surge tank.
  
  Fig 30: View Of 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.
INSTALL COLD START INJECTOR
1. Connect the cold start injector with the 2 bolts.
  
  Fig 31: Identifying 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.
INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to INSTALLATION - Step 1
INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE . Refer to INSTALLATION - Step 2
CONNECT NO. 2 VENTILATION HOSE . Refer to INSTALLATION - Step 3
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL . Refer to INSTALLATION - Step 93
ADD ENGINE COOLANT . Refer to ON-VEHICLE INSPECTION - Step 5
INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 3
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to INSTALLATION - Step 4
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to INSTALLATION - Step 5
INSTALL FRONT WIPER ARM HEAD CAP . Refer to INSTALLATION - Step 6
INSTALL ROOF DRIP SIDE FINISH MOULDING LH
INSTALL ROOF DRIP SIDE FINISH MOULDING RH
INSTALL FRONT UPPER FENDER PROTECTOR LH . Refer to INSTALLATION - Step 9
INSTALL FRONT UPPER FENDER PROTECTOR RH
HINT:

Installation procedure of the RH side is the same as that of the LH side.
INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 115
INSTALL ENGINE ROOM SIDE COVER LH . Refer to INSTALLATION - Step 116
INSTALL ENGINE ROOM SIDE COVER RH . Refer to INSTALLATION - Step 117
INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 118
CHECK FUNCTION OF THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to ON-VEHICLE INSPECTION - Step 1