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Fuel Injector, Intake Manifold: Installation

  1. INSTALL FUEL INJECTOR ASSEMBLY 
    1. Apply a light coat of spindle oil or gasoline to new O-rings, and install it to each injector.
      Fig 1: Identifying Fuel Injector Assembly
      G04376982Courtesy 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: Pushing Fuel Injector
      G04376983Courtesy 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 Insulators To Intake Manifold
      G04376984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Place the fuel delivery pipe and the 6 fuel injectors together to the intake manifold.
      Fig 4: Placing Fuel Delivery Pipe And Fuel Injectors
      G04376985Courtesy 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: Connecting Fuel Injector Connectors
      G04376986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
      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 fuel pipe clamp No.2.
      Fig 6: Connecting Fuel Tube Sub-Assembly
      G04376987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    1. Install a new gasket to the intake air surge tank.
    2. Using a 5 mm hexagon socket wrench, install the 4 bolts.

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

    3. Install the intake air surge tank with the 2 nuts and 2 bolts.
      Fig 7: Installing Intake Air Surge Tank With Nuts And Bolts
      G04376988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Nut 

      16 N m (163 kgf cm, 12 ft. lbf) Bolt 

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

    4. Connect the connector.
      Fig 8: Connecting Connector
      G04376989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the vacuum hose clamp with the bolt.

      Torque: 5.4 N m (55 kgf cm, 48 in. lbf) 

      Fig 9: Installing Vacuum Hose Clamp With The Bolt
      G04376990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the union to check valve hose.
    7. Connect the ventilation hose No.2.
      Fig 10: Connecting Ventilation Hose No. 2
      G04376991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the clamp and connect the throttle w/ motor body assembly connector.
      Fig 11: Connecting Water By-Pass Hoses To Throttle W/Motor Body Assembly
      G04376992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the vapor feed hose.
    10. Connect the 2 water by-pass hoses to the throttle w/motor body assembly.
  4. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 
    1. Install the 3 clamps and air cleaner cap with air cleaner hose.
    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.
      Fig 12: Connecting Fuel Vapor Feed Hose No.1
      G04376993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL COWL TOP PANEL OUTER (See step 21 under  INSTALLATION  ) 
  6. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY (See step 2 under  INSTALLATION  ) 
  7. INSTALL COWL TOP VENTILATOR LOUVER RH 
  8. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See step 3 under  INSTALLATION  ) 
  9. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See step 4 under  INSTALLATION  ) 
  10. ADD ENGINE COOLANT (See step 2 under  COOLANT  ) 
  11. CONNECT BATTERY NEGATIVE TERMINAL 
  12. CHECK FOR ENGINE COOLANT LEAKS (See step 3 under  COOLANT  ) 
  13. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  14. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Engage the 3 clips and install the v-bank cover.
      NOTE: Be sure to engage the clips in the order from A to B.
  15. PERFORM INITIALIZATION 
    1. Some systems need initialization when disconnecting the battery terminal.
      Fig 13: Installing V-Bank Cover And Clips
      G04376994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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