2004 Toyota Avalon XLFACTORY OEM SERVICE PROCEDURE

SFI System: Injector: Installation

  1. INSTALL INJECTORS AND DELIVERY PIPES 
    1. Install new insulator and grommet to each injector.
    2. Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector.
      Fig 1: Installing Insulator
      G02878924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches an O-ring of the injector.
    4. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors.
    5. Position the injector connector outward.
      Fig 2: Installing Injector
      G02878925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Place the 4 spacers in position on the intake manifold.
      Fig 3: Placing Spacers In Position
      G02878926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Apply a light coat of spindle oil or gasoline on the place where a intake manifold touches an O-ring of the injector.
    8. Place the delivery pipes and fuel pipe together with the 6 injectors in position on the intake manifold.
    9. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold.
    10. Temporarily install the bolt holding the No.1 fuel pipe to the intake manifold.
      Fig 4: Placing Delivery Pipes And Fuel Pipe
      G02878927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Check that the injectors rotate smoothly.

      HINT:

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

    12. Position the injector connector outward.
      Fig 5: Checking That Injectors Rotate Smoothly
      G02878928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Tighten the 4 bolts holding the delivery pipes to the intake manifold.

      Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) 

    14. Tighten the bolt holding the No.1 fuel pipe to the intake manifold.

      Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf) 

    Fig 6: Tightening Bolts Holding Delivery Pipes
    G02878929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT NO.1 FUEL PIPE 
    1. Align the alignment marks (white paint) on the No.1 fuel pipe.
      Fig 7: Aligning Alignment Marks
      G02878930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the No.1 fuel pipe (fuel tube connector) to the fuel filter.
      CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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