Fuel Injector Installation

Install new insulators to each fuel injector.

Apply a light coat of grease or gasoline to a new O-ring and install it to the injector.

Apply a light coat of grease or gasoline where the delivery pipe contacts the O-ring.

To install the fuel injector into the fuel delivery pipe, push the fuel injector while turning it right and left.

NOTICE:

1. Be careful not to twist the O-ring.
   
2. After installing the fuel injector, check that it turns smoothly. If not, reinstall the it with a new O-ring.
   

Position the injector connector outward.

Place the fuel delivery pipe and the 6 fuel injectors together to the intake manifold.

Temporarily install the 6 bolts which are used to hold the fuel delivery pipe to the intake manifold.

Check that the fuel injectors rotate smoothly.

HINT:

If fuel injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. If so, replace the O-rings.

Position the fuel injector connector outward.

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}

Connect the No. 1 fuel hose to the cylinder head cover with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the 6 fuel injector connectors.

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.

Check that the connector and fuel main pipe are securely connected by trying to pull them apart.

Install the fuel pipe clamp.

Install a new gasket to the intake air surge tank.

Install the intake air surge tank with the 2 nuts.

Torque:

16 N*m{163 kgf*cm, 12 ft.*lbf}

Using a 5 mm hexagon socket wrench, install the 4 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Install the 2 surge tank stays with the 4 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

For Chinese specification:
Connect the water hose joint with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

For except Chinese specification:
Connect the water by-pass pipe with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the 3 wire harness clamps.

Connect the IACV connector.

Connect the throttle motor connector.

Connect the ventilation hose to the ventilation valve.

Connect the hose to the surge tank.

Connect the 2 water by-pass hoses to the throttle body.

Install the air cleaner cap with air cleaner hose with the 4 clamps and hose clamp.

HINT:

Be sure to install the air cleaner assembly so that the screw part of the hose clamp is as shown in the illustration.

Install the VSV (for EVAP) to the air cleaner hose.

Connect the MAF meter connector and clamp to the air cleaner.

Connect the ventilation hose to the cylinder head cover with the clamp.

Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Torque:

12.7 N*m{130 kgf*cm, 9 ft.*lbf} for cylinder block drain cock plug

Add engine coolant.

Specified capacity:

9.1 liters (9.6 US qts, 8.0 lmp. qts)

NOTICE:

When pressing the radiator hose:

1. Wear protective gloves.
   

1. Be careful as the radiator hose is hot.
   

1. Keep your hands away from the radiator fan.
   

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   

1. Please contact your TOYOTA dealer for further details.
   

1. The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
   

Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Install the radiator cap and reservoir cap.

Bleed air from the cooling system.

NOTICE:

Before starting the engine to warm up the engine, turn the A/C switch OFF.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

   HINT:

   The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

   NOTICE:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   1. Be careful as the radiator hoses are hot.
      
   1. Keep your hands away from the radiator fan.
      

2. Maintain the engine speed at 2,000 to 2,500 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   NOTICE:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   1. Be careful as the radiator hoses are hot.
      
   1. Keep your hands away from the radiator fan.
      

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Check the coolant level in the radiator reservoir.
If the coolant level is low, add SLLC to the radiator reservoir FULL line.

Fill the radiator with coolant and attach a radiator cap tester.

Warm up the engine.

Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm, 17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

Start the engine, and check that there are no fuel leaks after performing maintenance anywhere on the system.

Start the engine, and check that there are no oil leaks after performing maintenance.

Install the V-bank cover with the 2 nuts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the side cover with the 2 clips and nut.

Install the intake duct seal with the 7 clips.

Install the under cover with the 10 bolts and 3 clips.

Perform initialization (Click here).

NOTICE:

Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

After the engine is warmed up, check that the maintained parts operate normally.