Fuel Injector: Installation

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FUEL INJECTOR ASSEMBLY
NOTE:
- Be careful not to drop the injectors when installing the delivery pipes.
- Do not apply any load to the injector in the horizontal direction.
1. Install a new grommet to each injector.
2. Apply a light coat of gasoline to each new O-ring and install one to each injector.
  
  Fig 1: Identifying O-Ring And Grommet Of Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 8 injectors.
  1. While turning each injector clockwise and counterclockwise, push it onto the delivery pipes.
  2. Position the injector connectors outward.
    
    Fig 2: Installing Injectors On Delivery Pipes
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place 8 new insulators on the intake manifold.
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
NOTE: Be careful not to drop the injectors when installing the delivery pipes.
1. Place the 2 delivery pipes and injector assemblies on the lower intake manifold.
2. Temporarily install the 4 nuts.
3. Install the front fuel pipe with the bolt, 4 new gaskets and 2 union bolts.
  Torque:
  
  for union bolt
  
  39 N*m (398 kgf*cm, 29 ft.*lbf)
  
  for bolt
  
  7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 3: Locating Front Fuel Pipe Bolt And Union Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the fuel return pipe with the 3 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 4: Identifying Fuel Return Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the fuel return hose to the fuel pressure regulator.
  
  Fig 5: Locating Fuel Return Hose Of Fuel Pressure Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check that the injectors rotate smoothly.
  HINT:
  
  If the injectors do not rotate smoothly, a probable cause is the incorrect installation of the O-rings. Replace the O-ring of the injector that does not rotate smoothly.
  
  Fig 6: Checking Injectors Rotate Smoothly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Position the injector connectors outward.
8. Tighten the 4 nuts holding the delivery pipes to the lower intake manifold.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
9. Connect the 8 injector connectors.
INSTALL ENGINE WIRE
1. Install the 2 wire clamps on the engine wire to the brackets on the RH delivery pipe.
2. Connect the engine wire clamps to the No. 1 engine hanger and engine wire bracket.
3. Install the engine wire protector with the 2 bolts.
  
  Fig 7: Identifying Wire Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL RETURN TUBE
1. Connect the fuel return tube (see PRECAUTION ).
  
  Fig 8: Locating Fuel Return Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL MAIN TUBE
1. Connect the fuel main tube (see PRECAUTION ).
2. Install the fuel pipe clamp.
  
  Fig 9: Locating Fuel Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THROTTLE BODY COVER BRACKET
1. Install the 2 throttle body cover brackets with the 2 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
CONNECT PURGE VSV
1. Install the purge VSV to the intake manifold with the bolt.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
2. Connect the purge line hose.
3. Connect the purge VSV connector.
  
  Fig 10: Locating Purge VSV And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 VENTILATION HOSE
1. Connect the No. 2 ventilation hose to the ventilation valve.
INSTALL AIR CLEANER HOSE ASSEMBLY (See INSTALLATION )
INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
CHECK FOR FUEL LEAK
1. Connect the Techstream to the DLC3.
2. Turn the ignition switch ON and Techstream main switch ON.
  NOTE: Do not start the engine.
3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
4. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.