Toyota Tacoma (2015-2018) Service Manual: Installation

Toyota Tacoma (2015-2018) Service Manual / 2gr-fks Fuel / Fuel Injector(for Direct Injection) / Installation

INSTALLATION

CAUTION / NOTICE / HINT

HINT:

Perform "Inspection After Repairs" after replacing the fuel injector assembly (See page PROCEDURE ).

PROCEDURE

1. INSTALL FUEL INJECTOR SEAL

(a) Apply engine conditioner to the fuel injector assembly area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector assembly and its grooves.

Text in Illustration

*a	Clean Area

NOTICE:

Do not clean the tip of the fuel injector assembly.
Do not use a wire brush to clean the fuel injector assembly.
If a fuel injector assembly is dropped or the tips of the fuel injector assemblies are struck, replace it with a new one.

(b) Apply engine oil to the fuel injector assembly contact surface of SST (guide). Then attach SST (guide) to the fuel injector assembly with the tapered inner portion facing the tip of the injector as shown in the illustration.

Text in Illustration

*a	SST (Guide)
*b	Tapered Inner Portion

SST: 09260-39021

09261-03020

Text in Illustration

*1	Fuel Injector Seal
*a	Correct
*b	Incorrect
*c	SST (Holder)

SST: 09260-39021

09261-03011

NOTICE:

Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal and correcting this problem is very complicated.

(d) Install SST (holder with injector seal) to the tip of the fuel injector assembly. Slide the fuel injector seal downward into the fuel injector assembly groove (injector connector side) with your fingers as shown in the illustration.

Text in Illustration

*a	SST (Holder)
*b	SST (Guide)

SST: 09260-39021

09261-03020

09261-03011

HINT:

Check that the fuel injector seal covers the circumference of the injector groove as shown in the illustration.

(e) Slowly slide SST (guide) toward the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.

Text in Illustration

*a	SST (Guide)

SST: 09260-39021

09261-03020

NOTICE:

Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the seal if it becomes damaged.

HINT:

Set SST (guide) so that its bottom surface and the fuel injector seal are flush.
If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.

(f) After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the fuel injector assembly groove.

Text in Illustration

*a	Normal
*b	Protruding
*c	Deformed
*d	Correct
*e	Incorrect

NOTICE:

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

2. INSTALL FUEL INJECTOR ASSEMBLY

HINT:

Perform "Inspection After Repairs" after replacing the fuel injector assembly (See page ).

(a) Install a new injector vibration insulator and a new C-ring to the fuel injector assembly.

Text in Illustration

*1	Fuel Injector Assembly
*2	C-ring
*3	Injector Vibration Insulator
*a	Tapered Side

NOTICE:

Install the injector vibration insulator aligning it with the tapered side of the fuel injector assembly.
Check that the C-ring is securely fit into the groove of the fuel injector assembly.

(b) Install a new No. 1 fuel injector back-up ring and a new O-ring as shown in the illustration.

Text in Illustration

*1	No. 1 Fuel Injector Back-up Ring	*2	O-ring
*3	No. 3 Fuel Injector Back-up Ring	-	-
*a	No. 1 Fuel Injector Back-up Ring Opening	*b	Overlapping
*c	Gap	*d	OK
*e	NG	-	-

NOTICE:

Check that there is no foreign matter or damage in the groove of the O-ring.
Do not mistake the direction of the No. 1 fuel injector back-up ring.
Do not install the No. 1 fuel injector back-up ring and O-ring in the wrong order.
Do not allow the opening of the No. 1 fuel injector back-up ring to separate or overlap as shown in the illustration.

(c) Set a new No. 3 fuel injector back-up ring so that it is level as shown in the illustration, push in the fuel injector assembly and install the No. 3 fuel injector back-up ring.

Text in Illustration

*1	Fuel injector assembly
*2	No. 3 Fuel Injector Back-up Ring
*a	Cutout

NOTICE:

Make sure that the No. 3 fuel injector back-up ring is oriented correctly.
After installing the O-ring, make sure there is no damage or foreign matter.

(d) Install the nozzle holder clamp to the fuel injector assembly.

(e) Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe and insert the fuel injector assembly.

Text in Illustration

*a	Protrusion
*b	Positioning Hole
	No gap

Text in Illustration

*a	QR Code
*b	Flow Classification Number

NOTICE:

Install 3 fuel injector assemblies with the same flow classification number (the number to the left of the QR code which is 6, 7 or 8) on each bank (6 fuel injector assemblies with the same flow classification number is also okay).
Make sure that there is no foreign matter or damage inside the fuel injector assembly insertion holes (fuel delivery pipe).
Do not get gasoline on the O-rings or inside the installation holes.
If the fuel injector assembly is difficult to insert, apply new engine oil to the chamfered part of the fuel injector assembly insertion hole of the fuel delivery pipe. Also, be careful as it is easier for the injector to fall out of the fuel delivery pipe in this case.
Keep the injector straight and do not tilt it when inserting it into the fuel delivery pipe.
Check that there is no gap between the fuel delivery pipe and the nozzle holder clamp.

3. INSTALL FUEL DELIVERY PIPE RH

(a) Connect the 3 connectors and install the No. 6 engine wire.

(b) Apply lubricant to the installation hole of the fuel injector assemblies.

(c) Insert the stud bolt into the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.

Text in Illustration

*a	Nut can be attached

NOTICE:

If a fuel injector assembly is dropped or the tips of the fuel injector assemblies are struck, replace it with a new one.
Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the fuel delivery pipe.
When inserting the fuel delivery pipe, push it in evenly without tilting it.

(d) Install the fuel delivery pipe RH by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

Text in Illustration

*1	Bolt
*2	Nut
*a	Front

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(e) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(f) Engage the clamp and connect the No. 6 engine wire

(g) Connect the fuel pressure sensor connector.

NOTICE:

Do not pull the wire harness of the fuel pressure sensor excessively.

4. INSTALL FUEL DELIVERY PIPE ASSEMBLY LH (FUEL PRESSURE SENSOR)

NOTICE:

Do not remove the fuel pressure sensor from the fuel delivery pipe assembly LH.
If a fuel pressure sensor is removed, replace the fuel delivery pipe assembly LH (fuel pressure sensor) with a new one.

(a) Connect the 3 connectors and install the No. 7 engine wire.

(b) Apply lubricant to the installation holes of the fuel injector assemblies.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Insert the stud bolt into the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.

Text in Illustration

*a	Nut can be attached

NOTICE:

If a fuel injector assembly is dropped or the tips of the fuel injector assemblies are struck, replace it with a new one.
Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the delivery pipe.
When inserting the fuel delivery pipe, push it in evenly without tilting it.

(e) Install the fuel delivery pipe assembly LH by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

Text in Illustration

*1	Bolt
*2	Nut
*a	Front

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(f) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(g) Engage the clamp and connect the No. 7 engine wire.

(h) Connect the fuel pressure sensor connector.

(i) Engage the 3 clamps and connect the No. 6 engine wire and No. 7 engine wire.

(j) Connect the 2 connectors.

5. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Temporarily install the 2 union nuts of the fuel delivery pipe RH and fuel delivery assembly LH to the No. 2 fuel pipe sub-assembly until they are completely fastened.

(b) Use a 17 mm union nut wrench, tighten the 2 union nuts of the No. 2 fuel pipe sub-assembly.

Text in Illustration

*a	Torque Wrench Fulcrum Length

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

If the 2 union nuts cannot be fastened, loosen the nuts of the fuel delivery pipe RH and fuel delivery pipe assembly LH, and then fasten both union nuts.
Do not adjust the torque in the loosening direction.
The No. 2 fuel pipe sub-assembly can be reused 10 times.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (See page ).
When using a union nut wrench (fulcrum length of 30 mm (1.181 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
This torque value is effective when the union nut wrench is parallel to the torque wrench.
Install the union nut wrench parallel with the torque wrench.

6. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

(See page Fuel Injector(for Port Injection) )

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