Fuel Injectors & Fuel Rails: Installation

Install NEW grommet to each fuel injector. Apply a light coat of gasoline to NEW "O" ring and install onto injector. Apply a light coat of gasoline to "O" ring on injector to ease installation into fuel rail.
Install fuel injectors into fuel rail by turning/twisting fuel injector from left to right in order to bottom injector into fuel rail. Place 4 NEW insulators and 2 NEW spacers into position on cylinder head. Insert fuel rail/injector assembly into insulators on cylinder head. Ensure fuel injectors rotate smoothly in insulators.
Position fuel injector electrical connectors upward. Install fuel rail mounting bolts and tighten to specification. See appropriate TORQUE SPECIFICATIONS table. Connect fuel inlet hose to fuel rail using 2 new washer gaskets. Tighten fuel inlet pipe union bolt to 22 ft. lbs. (29 N.m).
Connect fuel injector connectors. Connect fuel return hose and vacuum hose to fuel pressure regulator. Connect battery negative cable. Turn ignition on and check for fuel leaks.

Apply light coat of gasoline to NEW "O" rings and install 2 "O" rings to each injector. Install each injector into fuel rail so that injector electrical connector is opposite bolt hole for injector cover. See Figure.
Install fuel pressure regulator to fuel rail using hand pressure to fully bottom unit into rail. Turn regulator counterclockwise until vacuum pipe aligns with rail and fuel return pipe is 180 degrees opposite of fuel rail. Tighten lock nut to 22 ft. lbs. (29 N.m).
Install NEW insulator to each injector and install injector cover. Tighten 4 cover bolts to 69 INCH lbs. (7.8 N.m). Connect fuel inlet pipe to fuel rail. Tighten fuel pipe union bolt to 22 ft. lbs. (29 N.m), and fuel line mounting bolt to 69 INCH lbs. (29 N.m).
Install NEW insulator to each injector bottom. Position 3 fuel rail mounting spacers to intake manifold. Install fuel rail, with attached injectors, into intake manifold injector recesses. Install 3 fuel rail mounting bolts and tighten to 14 ft. lbs. (19 N.m).
Connect fuel return hose and vacuum hose to pressure regulator. Install wiring harness to intake manifold and position to mounting bolts on timing belt cover. Connect Gray colored injector connectors to No. 2 and No. 4 injectors. Connect Brown colored injector connectors to No. 1 and No. 3 injectors.
To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See the appropriate TORQUE SPECIFICATIONS table. After installation complete, turn ignition on and check for fuel leaks.

Install NEW grommet to each injector. Apply a light coat of gasoline to NEW "O" ring and install to injector. Install injectors to fuel rail by turning injector from left to right to bottom injector securely into rail.
Install 4 NEW injector insulators and 2 rail mounting spacers into positions on cylinder head. Install fuel rail/injectors assembly into position on cylinder head. Snug tighten 2 mounting bolts holding fuel rail to cylinder head.
Check that injectors rotate smoothly and each injector electrical connector is position upward, facing camshaft cover. If injectors DO NOT rotate smoothly, remove injector and replace damaged "O" rings. Tighten 2 fuel rail mounting bolts to 115 INCH lbs. (13 N.m).
Connect fuel return hose to fuel rail. Connect fuel inlet pipe to fuel rail with 2 NEW gaskets and pulsation dampener. Tighten pulsation dampener to 25 ft. lbs. (34 N.m). Connect injector harness connectors.
To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See the appropriate TORQUE SPECIFICATIONS table. After installation complete, turn ignition on and check for fuel leaks.

Fig 1: Positioning Injector Connectors (Celica & MR2 3S-GTE)