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Fuel Injector: Installation

  1. INSTALL INJECTOR AND DELIVERY PIPE 
    NOTE:
    • Be careful not to drop the injectors when installing the delivery pipe.
    • Since the O-ring may become stuck to the injector, do not apply a side load on it during the installation.
    1. Install a new grommet and insulator to each injector.
      Fig 1: Installing Grommet & Insulator To Each Injector
      G04436011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply a light coat of gasoline to a new O-ring and install it to each injector.
    3. While turning each injector clockwise and counterclockwise, push it into a delivery pipe. Install the 8 injectors.
      Fig 2: Pushing Injector Into Delivery Pipe
      G04436012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Position each injector connector outward.
    5. Place the 4 spacers and 8 new insulators on the intake manifold.
    6. Place the 2 delivery pipes and the injector assemblies on the lower intake manifold.
    7. Temporarily install the 4 nuts.
    8. Install the front fuel pipe with the bolt, 4 new gaskets and 2 union bolts.

      Torque: 

      • 39 N*m (400 kgf*cm, 29 ft.*lbf) for union bolt 
      • 7.5 N*m (77 kgf*cm, 66 in.*lbf) for bolt 
      Fig 3: Installing Front Fuel Delivery Pipe
      G04436013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Check that the injectors rotate smoothly.

      HINT:

      If the injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings in this case.

      Fig 4: Checking Injectors Rotates
      G04436014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Position the injector connector outward.
    11. Tighten the 4 nuts holding the delivery pipes to the lower intake manifold.

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

    12. Connect the 8 injector connectors.
  2. INSTALL FUEL RETURN PIPE 
    1. Connect the hose to the fuel pressure regulator.
    2. Install the pipe with the 3 bolts.

      Torque: 7.5 N*m (77 kgf*cm, 13 in.*lbf) 

      Fig 5: Installing Fuel Return Pipe
      G04436015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Observe these precautions when connecting the fuel tube connector.
    4. Check that there is no damage or contamination in the connected part of the pipe.
    5. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.
      Fig 6: Pushing Pipe Into Connector
      G04436016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. After finishing the connection, try to pull apart the pipe and the connector to confirm that they are securely connected.
      Fig 7: Pulling Apart Pipe To Confirm That Pipe Is Secured
      G04436017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the fuel pipe clamp to the connector.
      Fig 8: Installing Fuel Pipe Clamp To Connector
      G04436018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT ENGINE WIRE 
    1. Install the 2 wire clamps on the engine wire to the brackets on the delivery pipe RH.
    2. Connect the engine wire clamps to the No. 1 engine hanger and engine wire bracket.
    Fig 9: Connecting Engine Wire
    G04436019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL PURGE VSV 
    1. Install the purge VSV to the upper intake manifold with the bolt.
    2. Connect the purge line hose.
    3. Connect the purge VSV connector.
  5. CONNECT VENTILATION HOSE 
    1. Connect the ventilation hose to the ventilation valve.
  6. INSTALL FUEL PRESSURE PULSATION DAMPER 
    1. Install 2 new gaskets and the fuel main hose with the fuel pressure pulsation damper.
      Fig 10: Installing New Gaskets & Fuel Main Hose With Fuel Pressure Pulsation Damper
      G04436020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the union bolt by hand.
    3. Using SST, tighten the union bolt.

      SST 09612-24014 

      Torque: 

      • 33 N*m (340 kgf*cm, 24 ft.*lbf) for use with SST 
      • 39 N*m (400 kgf*cm, 29 ft.*lbf) for use without SST 
      Fig 11: Tightening Union Bolt Using Torque Wrench
      G04436021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  7. INSTALL INTAKE AIR CONNECTOR (See  INSTALLATION  ) 
  8. INSTALL V-BANK COVER (See  INSTALLATION  ) 
  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  10. PERFORM INITIALIZATION 
    1. Perform INITIALIZATION .
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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