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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 one to each injector.
      Fig 1: Identifying 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 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.
        Fig 2: Pushing Fuel Injector
        G04975018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install 6 new insulators to the intake manifold.
      Fig 3: Identifying Intake Manifold Insulators
      G04975010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Place the fuel delivery pipe and the 6 fuel injectors together to the intake manifold.
      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.
      Fig 4: Locating Fuel Injectors
      G04975009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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: Locating Fuel Injector Connectors
      G04997026Courtesy 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.
        Fig 6: Identifying Fuel Pump Clamp
        G04975022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 2 fuel pipe clamp.
  3. INSTALL INTAKE AIR SURGE TANK 
    NOTE: Do not apply oil to the bolts as listed below:
    INTAKE AIR SURGE TANK REFERENCE

    Oil Application Prohibited Bolt
    Bolt for surge tank and intake manifold
    Bolt for No. 1 surge tank stay and surge tank
    Bolt for No. 1 surge tank stay and cylinder head cover
    Bolt for throttle body bracket and surge tank
    Bolt for throttle body bracket and cylinder head cover
    1. Install a new gasket to the intake air surge tank.
    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 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 Intake Air Surge Tank With Nuts And Bolt
      G05248492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector.
      Fig 8: Locating Connector
      G04974478Courtesy 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: Locating Vacuum Hose Clamp With Bolt
      G04974477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the union to check valve hose.
    7. Connect the ventilation hose No. 2.
      Fig 10: Locating Ventilation Hose No. 2 And Check Valve Hose
      G04997043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the clamp and connect the throttle with motor body assembly connector.
    9. Connect the vapor feed hose.
    10. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
      Fig 11: Locating Water By-Pass Hoses
      G05405319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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) 

      Fig 12: Locating Air Cleaner Cap With Air Cleaner Hose And Clamps
      G04997045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  5. INSTALL COWL TOP PANEL OUTER  (See INSTALLATION )
  6. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY  (See INSTALLATION )
  7. INSTALL COWL TOP VENTILATOR LOUVER RH 
  8. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  9. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  10. ADD ENGINE COOLANT  (See REPLACEMENT )
  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  12. INSPECT FOR COOLANT LEAK  (See REPLACEMENT )
  13. INSPECT FOR FUEL LEAK  (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.
      Fig 13: Locating V-Bank Cover Clips
      G04997046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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