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Installation [12/2023 - ]: Procedure

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  1. INSTALL FUEL INJECTOR SEAL 
    1. GTY1228884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Injector Seal - -
      *a Area to be Cleaned *b SST (Guide)
      *c Chamfer *d SST (Holder)
      *e Correct *f Incorrect
      *g Normal *h Protruding
      *i Deformed - -
      1. Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the direct fuel injector assembly and its grooves.
        NOTE:
        • Do not clean the tip of the direct fuel injector assembly.
        • Do not use a wire brush to clean the direct fuel injector assembly.
        • If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.
      2. Apply engine oil to the direct fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the direct fuel injector assembly with the chamfer facing the tip of the direct fuel injector assembly as shown in the illustration.
        • SST: 09260-39021 
          1. 09261-03020
      3. Install a new fuel injector seal to SST (holder).
        • SST: 09260-39021 
          1. 09261-03011
        NOTE:

        Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal.

      4. Install SST (holder) with the fuel injector seal to the tip of the direct fuel injector assembly. Slide the fuel injector seal downward into the direct fuel injector assembly groove with your fingers as shown in the illustration.
        • SST: 09260-39021 
          1. 09261-03011
          2. 09261-03020

        HINT: 

        Check that the fuel injector seal is seated in the direct fuel injector assembly groove as shown in the illustration.

      5. Slowly slide SST (guide) toward the tip of the direct fuel injector assembly. When the direct fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 10 seconds or more to fully seat the fuel injector seal into the direct fuel injector assembly groove.
        • SST: 09260-39021 
          1. 09261-03020
        NOTE:

        Make sure the fuel injector seal is not pinched between SST (guide) and the edge of the direct fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

        HINT: 

        • Set SST (guide) so that its bottom surface is flush with the fuel injector seal.
        • If it is difficult to slide SST (guide) upward, slowly wiggle it from side to side while sliding it up the direct fuel injector assembly little by little.
      6. After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the direct fuel injector assembly groove.
        NOTE:

        If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

  2. INSTALL INJECTOR VIBRATION INSULATOR 
    1. GTY1233751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Direct Fuel Injector Assembly *2 Injector Vibration Insulator
      *a Taper - -
      1. Install a new injector vibration insulator to each direct fuel injector assembly.
        NOTE:

        Install the taper of the injector vibration insulator by aligning it with the taper of the direct fuel injector assembly.

  3. INSTALL C-RING 
    1. GTY1231405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install a new C-ring to each direct fuel injector assembly.
        NOTE:

        Check that the C-ring is securely seated in the groove of the direct fuel injector assembly.

  4. INSTALL NO. 1 FUEL INJECTOR BACK-UP RING 
    1. GTY1227940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Injector Back-up Ring *2 O-ring
      *a No. 1 Fuel Injector Back-up Ring Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -
      1. Install a new O-ring and No. 1 fuel injector back-up ring to each direct fuel injector assembly as shown in the illustration.
        NOTE:
        • Check that there is no foreign matter or damage on the O-ring groove of the direct fuel injector assembly.
        • Make sure that the No. 1 fuel injector back-up ring is installed in the correct orientation.
        • Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.
        • Check that the opening of the No. 1 fuel injector back-up ring is not overlapped or stretched as shown in the illustration.
        • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
  5. INSTALL NO. 3 FUEL INJECTOR BACK-UP RING 
    1. GTY1230119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Direct Fuel Injector Assembly *2 No. 3 Fuel Injector Back-up Ring
      *a Notch - -
      1. With the notch of a new No. 3 fuel injector back-up ring facing downward, install the No. 3 fuel injector back-up ring to each direct fuel injector assembly as shown in the illustration.
        NOTE:
        • Make sure that the No. 3 fuel injector back-up ring is installed in the correct orientation.
        • After installing the No. 3 fuel injector back-up ring, make sure there is no damage or foreign matter.
  6. INSTALL NOZZLE HOLDER CLAMP 
  7. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 
    1. GTY1231775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion *b Positioning Hole
      No Gap - -
      1. Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, and insert the direct fuel injector assembly.
        NOTE:
        • Make sure that there is no foreign matter or damage inside the direct fuel injector assembly installation holes (fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH).
        • Do not allow gasoline to get on the O-rings or inside the installation holes.
        • If it is difficult to insert the direct fuel injector assembly, apply new engine oil to the chamfer of the direct fuel injector assembly installation hole of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH. Be careful not to allow the direct fuel injector assembly to fall out of the fuel delivery pipe with sensor assembly LH or fuel delivery pipe RH.
        • Do not tilt the direct fuel injector assembly when inserting it into the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.
        • Check that there is no gap between the fuel delivery pipe with sensor assembly LH, fuel delivery pipe RH and the nozzle holder clamp.
        • GTY614309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a QR Code
          *b Flow Classification Number

          Make sure the 3 fuel injector assemblies of each bank all have the same flow classification number and that the flow classification number is 6, 7 or 8 (it is acceptable for both banks to have the same flow classification number).

  8. INSTALL FUEL DELIVERY PIPE RH 
    1. Fig 1: Fuel Delivery Pipe RH Tightening Sequence
      GTY1236879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protruding enough to install nut - -
      Bolt Nut
      1. Connect the 3 direct fuel injector assembly connectors and install the No. 6 engine wire.
      2. Apply lubricant to the direct fuel injector assembly installation holes of the cylinder head sub-assembly.
      3. Temporarily install the fuel delivery pipe RH so that the stud bolts protrude enough to install the nuts.
        NOTE:
        • If a direct fuel injector assembly is dropped or the tip of a direct fuel injector assembly is struck, replace it with a new one.
        • Check that there is no foreign matter or damage on the direct fuel injector assembly installation holes of the cylinder head sub-assembly.
        • When installing the fuel delivery pipe RH, push it in evenly without tilting it.
      4. Install the fuel delivery pipe RH by uniformly tightening the 2 bolts and 2 nuts in the order shown in the illustration.

        Torque: 26 N.m (265 kgf/cm, 19 ft.lbf) 

      5. Engage the clamp to connect the No. 6 engine wire to the fuel delivery pipe RH.
      6. Install the bolt.

        Torque: 8 N.m (82 kgf/cm, 71 in.lbf) 

  9. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH 
    1. Fig 2: Fuel Delivery Pipe With Sensor Assembly LH Tightening Sequence
      GTY1241262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protruding enough to install nut - -
      Bolt Nut
      1. Connect the 3 direct fuel injector assembly connectors and install the No. 7 engine wire.
      2. Apply lubricant to the direct fuel injector assembly installation holes of the cylinder head LH.
      3. Temporarily install the fuel delivery pipe with sensor assembly LH so that the stud bolts protrude enough to install the nuts.
        NOTE:
        • If a direct fuel injector assembly is dropped or the tip of a direct fuel injector assembly is struck, replace it with a new one.
        • Check that there is no foreign matter or damage on the direct fuel injector assembly installation holes of the cylinder head LH.
        • When installing the fuel delivery pipe with sensor assembly LH, push it in evenly without tilting it.
      4. Install the fuel delivery pipe with sensor assembly LH by uniformly tightening the 2 bolts and 2 nuts in the order shown in the illustration.

        Torque: 26 N.m (265 kgf/cm, 19 ft.lbf) 

      5. Engage the clamp to connect the No. 7 engine wire to the fuel delivery pipe with sensor assembly LH.
      6. Install the bolt.

        Torque: 8 N.m (82 kgf/cm, 71 in.lbf) 

      7. Connect the fuel pressure sensor connector.
  10. INSTALL WIRE HARNESS CLAMP BRACKET 
  11. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY 
    1. GTY1229331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17 mm Union Nut Wrench *b Torque Wrench Fulcrum Length
      1. Temporarily install the No. 2 fuel pipe sub-assembly to the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH and tighten the 2 union nuts by hand.
      2. Using a 17 mm union nut wrench, tighten the 2 union nuts of the No. 2 fuel pipe sub-assembly.

        Specified tightening torque 

        Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

        NOTE:
        • If the 2 union nuts cannot be fastened, loosen the nuts of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, and then fasten both union nuts.
        • Do not adjust the torque in the loosening direction.

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [09/2023 - ]

        • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
  12. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 

    Refer to INSTALLATION [12/2023 - ] 

  13. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing a direct fuel injector assembly.

      Refer to INITIALIZATION [12/2023 - ]

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