Installation (To 12/2010): Installation

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

INSTALL FUEL INJECTOR ASSEMBLY
1. Apply a light coat of spindle oil or gasoline to new O-rings, and install one to each injector.
  
  Fig 1: Identifying Fuel Injector And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts the O-ring.
  
  Fig 2: Positioning Fuel Injector Connector Outward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
4. Position the fuel injector connector outward.
  NOTE:
  - Be careful not to twist the O-ring.
  - After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
5. Install 6 new insulators to the intake manifold.
  
  Fig 3: Installing Intake Manifold Insulators
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Place the fuel delivery pipe and the 6 fuel injectors together to the intake manifold.
  
  Fig 4: Locating Fuel Delivery Pipe And Fsteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
7. Temporarily install the 6 bolts which are used to hold the fuel delivery pipe to the intake manifold.
  NOTE:
  After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
8. Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
9. Connect the 6 fuel injector connectors.
  
  Fig 5: Locating Fuel Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TUBE SUB-ASSEMBLY
1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
  
  Fig 6: Connecting Fuel Tube Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check that there is no damage or foreign objects on the connected part of the fuel pipe.
  - After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
2. Install the No. 2 fuel pipe clamp.

INSTALL INTAKE AIR SURGE TANK

NOTE:

Do not apply oil to the bolts as listed below:

Oil Application Prohibited Bolt
Bolt for surge tank and intake manifold
Bolt for No. 1 surge tank stay and surge tank
Bolt for No. 1 surge tank stay and cylinder head cover
Bolt for throttle body bracket and surge tank
Bolt for throttle body bracket and cylinder head cover

Install a new gasket to the intake air surge tank.

Fig 7: Locating Intake Air Surge Tank Nuts And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a 5 mm hexagon socket wrench, install the 4 bolts. (^* 1)
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
Install the intake air surge tank with the 2 nuts and 2 bolts. (^* 2)
Nut

Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)

Bolt

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Install the vacuum hose clamp with the bolt.

Fig 9: Locating Vacuum Hose Clamp And Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
Connect the union to check valve hose.

Fig 10: Identifying Vacuum Hoses Connections
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Connect the ventilation hose No. 2.
Install the clamp and connect the throttle with motor body assembly connector.

Fig 11: Identifying Throttle Body, Water By-Pass Hoses, Vapor Feed Hose And Harness Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Connect the vapor feed hose.
Connect the 2 water by-pass hoses to the throttle with motor body assembly.

INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
1. Install the 3 clamps and air cleaner cap with air cleaner hose.
  
  Fig 12: Installing Air Cleaner Cap With Air Cleaner Hose And Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the hose clamp bolt.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
3. Connect the air flow meter connector.
4. Connect the ventilation hose No. 1.
5. Connect the 3 vacuum hoses.
6. Connect the fuel vapor feed hose No. 1.
INSTALL COWL TOP PANEL OUTER . Refer to INSTALLATION - Step 19
INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY . Refer to INSTALLATION - Step 2
INSTALL COWL TOP VENTILATOR LOUVER RH
INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH . Refer to INSTALLATION - Step 3
INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH . Refer to INSTALLATION - Step 4
ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
INSPECT FOR COOLANT LEAK . Refer to REPLACEMENT - Step 3
INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Engage the 3 clips and install the V-bank cover.
  
  Fig 13: Identifying V-Bank Cover And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be sure to engage the clips in the order from A to B.