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Fuel Injector: Installation

  1. INSTALL FUEL INJECTOR ASSEMBLY 
    1. Apply a light coat of spindle oil or gasoline to new O-rings, and install them to each injector.
      Fig 1: Identifying Fuel Injector With O-Rings
      G04975017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts the O-ring.
    3. Push the fuel injector while turning it to install the injector 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.
        Fig 2: Pushing Fuel Injector
        G04975018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install 6 new insulators to the intake manifold.
      Fig 3: Locating Insulators And Intake Manifold
      G05138184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Place the fuel delivery pipe which has the 6 fuel injectors installed to it in position on the intake manifold.
      NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
      7. Fig 4: Locating Fuel Delivery Pipe And Fuel Injectors
      G04975009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.
      NOTE: After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.
    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
      G04975008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Push in the tube connector onto the pipe until the tube connector makes a "click" sound.
      NOTE:
      • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
    2. Install the No. 2 fuel pipe clamp.
    Fig 6: Locating Fuel Tube Sub-Assembly
    G05138197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    NOTE: DO NOT apply oil to the bolts listed below:
    TIGHTENING PARTS SPECIFICATION

    Tightening Parts
    Surge Tank and Intake Manifold
    No. 1 Surge Tank Stay and Surge Tank
    Throttle Body Bracket and Surge Tank
    1. Install a new gasket to the intake air surge tank assembly.
    2. Using a 5 mm hexagon socket wrench, install the 4 bolts. (*1)

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

    3. Install the intake air surge tank assembly with the 2 nuts and 2 bolts. (*2)

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

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

      Fig 7: Locating Air Surge Tank Assembly With Nuts And Bolts
      G05138180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector.
      Fig 8: Locating Connector
      G04974478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the union to check valve hose. (*5)
    6. Connect the No. 1 ventilation hose. (*4)
      Fig 9: Locating Valve Hose And Union
      G05138178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the clamp and connect the throttle with motor body assembly connector. (*3)
    8. Connect the vapor feed hose assembly. (*2)
    9. Connect the 2 water by-pass hoses to the throttle with motor body assembly. (*1)
      Fig 10: Locating Clamp, Throttle With Motor Body Assembly Connector
      G05138177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 
    1. Install the 2 bolts and air cleaner cap sub-assembly.
      Fig 11: Locating Air Cleaner Cap Sub-Assembly And Bolts
      G05138176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the No. 2 ventilation hose and air cleaner hose band.
    3. Connect the vacuum hose (EVAP) to the air cleaner hose.
      Fig 12: Locating Vacuum Hose (EVAP) And Air Cleaner Hose
      G05136359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 3 vacuum hoses.
    Fig 13: Locating Vacuum Hoses
    G05136358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. ADD ENGINE COOLANT  (See REPLACEMENT )
  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  7. INSPECT FOR ENGINE COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  8. INSTALL NO. 1 ENGINE UNDER COVER 
  9. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION  )
  10. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  11. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT 
    1. Install the 7 bolts and the cowl top panel sub-assembly outer front.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

    2. Connect the fuel pump resistor connector.
    3. Connect the wire harness clamp.
      Fig 14: Locating Cowl Top Panel Sub-Assembly Outer Front
      G05138173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 1 COWL TOP TO COWL BRACE INNER 
    1. Install the 2 bolts and the No.1 cowl top to cowl brace inner.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

    Fig 15: Locating Cowl Top To Cowl Brace Inner And Bolts
    G05138172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  14. INSTALL FRONT WIPER ARM LH  (See INSTALLATION )
  15. INSTALL FRONT WIPER ARM RH  (See INSTALLATION )
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