FUEL INJECTOR INSTALLATION


  1. INSTALL INJECTOR ASSEMBLY


    1. Apply a light coat of grease or gasoline to new O-rings and install them to the injector spacers.

      Note

      Make sure that the O-rings are installed between the parts correctly.

    2. Install the injection spacers.

    3. Apply a light coat of grease or gasoline to the place where the delivery pipe touches the O-ring.

    4. A003BQ7

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

      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.

  2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A003FEE

      Install the 4 spacers to the cylinder head.

    2. Install the delivery pipe spacers.

    3. A003GG1

      Temporarily install the 2 bolts and fuel delivery pipe together with the 4 injectors.

      Note


      • Do not drop the fuel injector when installing the fuel delivery pipe.

      • Make sure that the fuel injector turns smoothly.

    4. Fully tighten the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 10 ft.*lbf }

    5. Apply a light coat of grease or gasoline to the place where the delivery pipe touches the O-ring.

    6. Install the 2 bolts and pressure pulsation damper assembly.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    7. Connect the 2 fuel hoses.

  3. INSTALL FUEL HOSE


    1. Align the connector and pipe. Push on the connector until the retainer locks with a click sound. Click here

    2. Pull the connector to check that the connector is securely connected. Click here

    3. A003F9NE01

      Install the connector and lock it with the fuel hose connector cover. Click here

  4. INSTALL THROTTLE BODY ASSEMBLY


    1. A003HT7E01

      Install a new gasket onto the intake manifold.

      Tech Tips

      Fit the gasket to the cutout of the intake manifold.

    2. A003CU9E02

      for Type A:

      Install the throttle body assembly with the 2 bolts and 2 nuts. (A)

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    3. for Type B:

      Install the throttle body assembly with the 4 bolts. (A)

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Connect the water by-pass hose, and slide the clamp to secure it. (B)

    5. Connect the No. 2 water by-pass hose, and slide the clamp to secure it. (C)

    6. Connect the throttle motor connector. (D)

  5. INSTALL INTAKE AIR CONNECTOR


    1. Temporarily install the intake air connector to the throttle body assembly.

    2. A003DHQE03

      Connect the No. 2 ventilation hose and vacuum hose, and slide the clamp to secure it. (A)

    3. Install the intake air connector with the 2 bolts. (B)

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Tighten the 2 hose clamp bolts. (C)

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

  6. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole cover with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  7. INSTALL FRONT DOOR SCUFF PLATE RH

  8. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. A003DBM

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  9. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. A003GD3

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  10. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block water drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Rear Heater 11.2 liters (11.8 US qts, 9.9 Imp. qts)
      w/ Rear Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips

      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 is a combination of low phosphates and organic acids).

    4. Remove the 2-way that is located near the throttle body assembly.

    5. When air is bled and the engine coolant drains out, install the 2-way.

    6. Add coolant through the radiator reservoir assembly filler opening until the coolant reaches the B line and install the radiator reservoir cap sub-assembly. [*1]

    7. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fans.

      Note


      • Immediately after starting the engine, if the radiator reservoir assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.

      • Do not start the engine when there is no engine coolant in the radiator reservoir assembly.

      • Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough engine coolant, the engine may overheat.

      Tech Tips


      • Press the No. 2 and No. 3 radiator hoses several times by hand, and then check the level of the engine coolant.

      • The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    8. Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]

    9. Check the engine coolant level in the radiator reservoir assembly. [*4]

      Tech Tips


      • If the engine coolant level is below the LOW line, repeat step *1 through *4.

      • If the engine coolant level is above the FULL line, drain engine coolant until the engine coolant level is between the FULL and LOW lines.

  11. CHECK FOR ENGINE COOLANT LEAKAGE


    1. Check that the engine coolant level is between the LOW and FULL lines when the engine is cold. If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant (SLLC)" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the FULL line.

      Note

      Do not substitute plain water for engine coolant.

  12. CONNECT BATTERY NEGATIVE CABLE

  13. INSPECT FOR FUEL LEAKS


    1. When using the intelligent tester


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to the on position and intelligent tester main switch ON.

        Note

        Do not start the engine.

      3. Select the Active Test mode on the intelligent tester.

        Tech Tips

        Please refer to the intelligent tester operator's manual for further details.

    2. When not using the intelligent tester.


      1. A003CJUE01

        Disconnect the fuel pump connector.

      2. Using a service wire, connect terminals FP and +B of the relay block.

        Note

        Pay attention to the terminal connecting position to avoid a malfunction.

      3. Turn the ignition switch to the ON position, and check that the fuel pump operates.

        Note

        Do not start the engine.

    3. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.

    4. Check that the pulsation damper screw rises up when the fuel pump operates.

      If operation is not as specified, check the following parts:


      • Fusible link

      • Fuel pump

      • Wiring connections

      • ECM

      • Fuses

    5. Turn the ignition switch off.

    6. Disconnect the intelligent tester from the DLC3.