FUEL INJECTOR (For Direct Injection): Installation: Installation

1. Apply engine oil to the threaded portion of the fuel delivery pipe.
   NOTE: Make sure there is no gasoline on the threaded part of the fuel delivery pipe plug and fuel delivery pipe.
2. Install 2 new gaskets and the 2 fuel delivery pipe plugs to the fuel delivery pipe and No. 2 fuel delivery pipe.

   Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

1. Install 2 new O-rings, 2 new No. 1 backup rings, 2 new No. 2 backup rings and 2 new E-rings to the 2 fuel pipe support sub-assemblies as shown.
   Fig 1: Identifying New O-Rings, New No. 1 Backup Rings, New No. 2 Backup Rings And New E-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check that there is no foreign matter or damaged areas in the fuel pipe support sub-assembly O-ring groove.
   • Check that the No. 1 backup ring is 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.
   • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
2. Apply engine oil to the O-ring.
   NOTE: Make sure there is no gasoline on the O-ring and inside the installation hole.
3. Install the 2 fuel pipe support sub-assemblies to the fuel delivery pipe and No. 2 fuel delivery pipe with the 4 bolts.

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

1. Apply engine conditioner to the clean area shown. Using a piece of cloth, clean carbon deposits from the injector and its grooves.
   Fig 2: Applying Engine Conditioner To 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 is 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.
   Fig 3: Identifying Fuel Injector Seal (Tapered Inner Portion)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09260-39015 
     • 09268-03020
3. Install a new injector seal to SST (holder).
   Fig 4: Identifying Injector Seal And SST

   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.
   Fig 5: Identifying Injector Seal To SST

   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.

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 6: Identifying 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.
   • After using SST (guide) to settle the seal into the groove, return SST (guide) to its position labeled B.
6. Install a new injector seal to SST (holder).
   Fig 7: Identifying Injector Seal And SST

   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.
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.
   Fig 8: Identifying SST Holder With Injector Seal

   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. If it does, replace it with a new one.

   HINT: 

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

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, hold the position for 5 seconds or more to fully align the seal into the injector groove.
   Fig 9: Identifying Injector Seal, SST Guide And Holder

   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 it is difficult to slide 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 10: Identifying SST 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.
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, hold the position for 5 seconds or more to fully align the seal into the injector groove.
    Fig 11: Identifying Injector Seal With SST

    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.

    If the seal is scratched, deformed or protruding from the groove, replace it with a new one.

    Fig 12: Identifying Correct And Incorrect Position 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 a new E-ring to the fuel injector as shown.
   Fig 13: Identifying Fuel Injector Alignment Opening

   Courtesy 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.
   • 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.
      Fig 14: Identifying Injector Nozzle Holder Clamp

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      • The injector connectors can be differentiated by the color of the insulators, which are black, yellow, green or brown. Install the injectors so that insulators are the same color for a given bank.
      • 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 15: Identifying Injector Connectors

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 4 new injector vibration insulators to the cylinder head.
2. Apply lubricant to the injector seal and installation holes.
3. Install the delivery pipe (with injectors) to the cylinder head with the 5 bolts.
   Fig 16: Identifying Fuel Delivery Pipe Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   NOTE:

   • If an injector is dropped or the tips of the injectors 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.
4. Connect the 4 injector connectors.
   Fig 17: Identifying Injector Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the fuel pressure sensor connector.
   Fig 18: Identifying 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 injector seal and installation holes.
3. Install the delivery pipe (with injectors) to the cylinder head with the 5 bolts.
   Fig 19: Identifying Delivery Pipe Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   NOTE:

   • If an injector is dropped or the tips of the injectors 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.
4. Connect the 4 injector connectors.
   Fig 20: Identifying Injector Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the No. 3 fuel hose.
   Fig 21: Identifying No. 3 Fuel Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the hose to the PCV valve.
   Fig 22: Identifying Ventilation Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the fuel pipe.
   Fig 23: Identifying No. 4 Fuel Pipe Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 19 mm union nut wrench, tighten the fuel pipe in the order shown.

   without union nut wrench 

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

   with union nut wrench 

   Torque: 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 union nut wrench and torque wrench are connected in a straight line.

1. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown.
   Fig 27: Identifying O-Ring, Backup Rings (No. 1 And No. 2) And E-Ring

   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.
   • 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 28: View Of Installing No. 3 Fuel Pipe To Delivery Pipe With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the No. 3 fuel pipe to the fuel pump.
   Fig 29: Identifying Fuel Pipe

   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. 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.
   Fig 30: Tightening Union Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   without union nut wrench 

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

   with union nut wrench 

   Torque: 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 union nut wrench and torque wrench are connected in a straight line.
6. Connect the fuel pump connector.

HINT: 

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

1. Install the fuel pressure pulsation damper. Refer to INSTALLATION .

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