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Fuel Injector: Installation

  1. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the injector area shown in the illustration. Using a cloth, clean carbon deposits from the injector and its grooves.
      Fig 1: Identifying Fuel Injector Seal
      G04018619Courtesy 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, replace it with a new one.
      • Be extremely careful not to touch or strike the tips of the injectors.
    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: Attaching SST (Guide) To Injector With Tapered Inner Portion
      G04018620Courtesy 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: Identifying Injector Seal To SST (Holder)
      G04018621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install SST (holder with injector seal) to the tip of the injector. Using your fingers, slide the seal downward into the injector groove (injector connector side), as shown in the illustration.

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

      HINT:

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

      Fig 4: Identifying SST (Holder With Injector Seal) To Tip Of Injector
      G04018622Courtesy 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 (09268-03010, 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.
        Fig 5: Pressing Downward On Injector Seal (Injector Connector Side)
        G04018623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install a new injector seal to the injector groove (injector tip side) as shown in the illustration.

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

      Fig 6: Identifying New Injector Seal To Injector Groove (Injector Tip Side)
      G04018624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check that the seal covers the circumference of the injector groove as shown in the illustration.

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

      NOTE: Make sure 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.
      Fig 7: Checking Seal Covers Circumference Of Injector Groove
      G04018625Courtesy 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 there is difficulty sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.
        Fig 8: Sliding SST (Guide) Tip Of Injector
        G04018626Courtesy 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 (09268-03010, 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.
      Fig 9: Pressing Downward On Injector Seal (Injector Tip Side)
      G04018627Courtesy 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 there is difficulty sliding SST upward, slowly wiggle it from side to side while sliding it up the injector little by little.
        Fig 10: Sliding SST (Guide) Tip Of Injector
        G04018628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. After installing the seals, check that the seal is not scratched, deformed or protruding from the injector groove.
      NOTE: If scratched, deformed or protruding from the groove, replace it with a new one.
  2. 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 11: Identifying Fuel Injector
      G04018629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 12: Identifying Backup Ring
      G04018630Courtesy 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 installation direction of the No. 1 and No. 2 backup ring are correct.
      • Make sure 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: Identifying Nozzle Holder Clamp
      G04018631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure there is no gap between the delivery pipe and clamp.
      • Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
      • Insert the injector straight into the delivery pipe without tilting it.
  3. 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
      G04018632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If an injector is dropped, replace it with a new one.
      • Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
      • Be extremely careful not to touch or strike the tips of the injectors.
      • 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.

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

    5. Connect the 3 connectors and 2 clamps.
  4. INSTALL NO. 2 FUEL DELIVERY PIPE 
    1. Install a new injector vibration insulator to the cylinder head.
    2. Apply lubricant to the installation hole of the injector.
      Fig 15: Identifying Connectors And Clamps
      G04018633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Delivery Pipe
      G04018634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If an injector is dropped, replace it with a new one.
      • Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
      • Be extremely careful not to touch or strike the tips of the injectors.
      • 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.

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

    5. Connect the 3 connectors and 3 clamps.
      Fig 17: Tightening Bolts And Nuts
      G04018635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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
      G04018636Courtesy 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 installation directions of the No. 1 and No. 2 backup ring are correct.
      • Make sure 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. Using your hand, press the fuel pipe and delivery pipe together until there is no gap between them. Then install the No. 3 fuel pipe with the 4 bolts.

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

  6. CONNECT 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 19: Pressing Fuel Pipe And Delivery Pipe
      G04018637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 20: Identifying New O-ring, New Backup Rings
      G04018638Courtesy 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 installation directions of the No. 1 and No. 2 backup rings are correct.
      • Make sure 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.
      NOTE: Do not install the bolt at this time.
  7. INSTALL HIGH PRESSURE SIDE FUEL PUMP (see  INSTALLATION   ) 
  8. INSTALL NO. 2 FUEL PIPE 
    1. Install the fuel pipe to the delivery pipe with the 2 bolts.

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

      Fig 21: Identifying Fuel Pipe To Delivery Pipe With Bolts
      G04018639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 1 FUEL PIPE 
    1. Install the fuel pipe with the 2 bolts.

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

    2. Connect the No. 1 fuel pipe hose.
      Fig 22: Identifying Fuel Pipe With Bolts
      G04018640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FUEL PRESSURE PULSATION DAMPER 
    1. Install a new gasket and the fuel pulsation damper to the fuel pump.

      Torque: 40 N*m (408 kgf*cm, 28 ft.*lbf) 

      Fig 23: Identifying New Gasket And Fuel Pulsation Damper To Fuel Pump
      G04018641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL INTAKE MANIFOLD 
    1. Install a new gasket and the intake manifold with the 4 bolts and 4 nuts.

      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.
      Fig 24: Identifying SCV Position Sensor Connector
      G04018642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL INTAKE AIR SURGE TANK 
    1. Install a new gasket to the intake air surge tank.
    2. Install the intake air surge tank with the 2 nuts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    3. Using a 5 mm hexagon socket wrench, install the 7 bolts.

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

    4. Install the 2 surge tank stays with the 4 bolts.

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

      Fig 25: Identifying Intake Air Surge Tank With 2 Nuts
      G04018643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 26: Identifying Surge Tank Stays With Bolts
      G04018644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 wire harness clamps.
    6. Connect the water hose joint with the bolt.

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

    7. Install the intake manifold stay with the 2 bolts.

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

    8. Connect the wire harness clamp to the intake air surge tank.
    9. Connect the IACV connector.
    10. Connect the throttle motor connector.
  13. CONNECT FUEL MAIN TUBE 
    NOTE: Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.
    1. Connect the connector to the fuel main pipe. Push the two parts together firmly until a "click" sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.
      Fig 27: Pushing Down On Connector Cover
      G04018645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the connector and fuel main pipe are securely connected by trying to pull them apart.
      Fig 28: Checking Connector And Fuel Main Pipe
      G04018646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the fuel pipe clamp.
      Fig 29: Identifying Fuel Pipe Clamp
      G04018647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT VENTILATION HOSE 
    1. Connect the ventilation hose to the ventilation valve.
      Fig 30: Identifying Ventilation Hose To Ventilation Valve
      G04018648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the hose to the surge tank.
      Fig 31: Identifying Hose To Surge Tank
      G04018649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL ENGINE REAR COVER 
    1. Install the engine rear cover with the 3 clips.
      Fig 32: Identifying Engine Rear Cover With 3 Clips
      G04018650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. CONNECT HEATER WATER OUTLET HOSE 
    1. Connect the hose to the pipe.
      Fig 33: Identifying Hose To Pipe
      G04018651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. CONNECT HEATER WATER INLET HOSE 
    1. Connect the hose to the pipe.
  19. CONNECT WATER BYPASS HOSE (See  ON-VEHICLE INSPECTION  ) 
  20. REMOVE COLD START INJECTOR (see  REMOVAL   ) 
  21. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See  INSTALLATION  ) 
  22. CONNECT NO. 2 VENTILATION HOSE (See  INSTALLATION  ) 
    Fig 34: Identifying Hose To Pipe
    G04018652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  24. ADD ENGINE COOLANT (See  ON-VEHICLE INSPECTION  ) 
  25. CHECK FOR COOLANT LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  26. CHECK FOR FUEL LEAKAGE 
    1. Start the engine, and check that there are no fuel leaks after performing maintenance anywhere on the system.
  27. CHECK FOR ENGINE OIL LEAKAGE 
    1. Start the engine, and check that there are no oil leaks after performing maintenance.
  28. INSTALL V-BANK COVER (See  INSTALLATION  ) 
  29. INSTALL ENGINE ROOM SIDE COVER RH (See  INSTALLATION  ) 
  30. INSTALL COOL AIR INTAKE DUCT SEAL (See  INSTALLATION  ) 
  31. INSTALL ENGINE UNDER COVER (See  INSTALLATION  ) 
  32. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  33. WARM UP ENGINE 
    1. After the engine is warmed up, check that the maintained parts operate normally.
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