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Fuel Injector ASSY: Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION   ) 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. REMOVE V-BANK COVER 
    1. Remove the 2 nuts and V-bank cover.
  4. REMOVE AIR CLEANER INLET NO.1 
  5. REMOVE INTAKE AIR CONNECTOR PIPE 
    1. Disconnect the air hose and ventilation hose No. 1.
    2. Loosen the hose clamp.
    3. Remove the bolt and intake air connector pipe.
  6. REMOVE V-BANK COVER BRACKET NO.1 
  7. REMOVE V-BANK COVER BRACKET NO.2 
  8. REMOVE V-BANK COVER BRACKET NO.3 
  9. REMOVE V-VANK COVER BRACKET NO.4 
  10. REMOVE VACUUM SWITCHING VALVE ASSY 
  11. DISCONNECT ENGINE WIRE 
    Fig 1: Disconnecting Wire Clamps From Wire Clamp Bracket On RH Delivery Pipe
    G02998984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe.
  12. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Disconnect the fuel delivery pipe and fuel pipe by removing both right and left pulsation dampers.
    2. Remove the gasket.
    Fig 2: Identifying Fuel Delivery Pipe
    G02998985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL DELIVERY PIPE SUB-ASSY 
    1. Remove the installation bolts of the water by-pass pipe No. 1 and No. 2.
    2. Disconnect the connector.
    3. Remove the 2 bolts.
    4. Remove the fuel delivery pipe No. 1 by pulling it straight upward holding both the ends.
  14. REMOVE FUEL DELIVERY PIPE SUB-ASSY NO.2 
    1. Disconnect the connector.
    2. Remove the 2 bolts.
    3. Remove the fuel delivery pipe No. 2 by pulling it straight upward holding both the ends.
  15. REMOVE FUEL INJECTOR ASSY 
    1. Remove the injector from the intake manifold.
      NOTE: Pull upward on the injector, Adding force in the horizontal direction may cause the O-ring to become stuck.
    2. Remove the O-ring, grommet and vibration insulator from the injector.
    Fig 3: Installing O-Ring, Grommet And Vibration Insulator From Injector
    G02998986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FUEL INJECTOR ASSY 
    1. Install a new grommet and vibration insulator to the injector.
    2. Check the injector's grooves (where O-rings are installed) for foreign matter or damage. Apply gasoline to 2 new O-rings and install them to the injector's grooves.
    3. To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth. Install the 4 injectors.
    4. Check that the injector can rotate smoothly.
    NOTE: When the injector cannot rotate smoothly, the O-ring may be caught on something. Remove the injector, remove the faulty O-ring, install a new O-ring and reinstall the injector.
  17. INSTALL FUEL DELIVERY PIPE SUB-ASSY NO.2 
    1. Install the injector (with delivery pipe) to the intake manifold.
    2. Under the above condition, turn the injector both ways by approximately 45 degrees.
    3. Inserting a spacer in between, install the delivery pipe (with injector) with the 2 nuts.
    1. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 
  18. INSTALL FUEL DELIVERY PIPE SUB-ASSY 
    1. Install the injector (with delivery pipe) to the intake manifold.
    2. Under the above condition, turn the injector both ways by approximately 45 degrees.
    3. Inserting a spacer in between, install the delivery pipe (with injector) with the 2 nuts.
    1. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 
  19. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Inserting 2 new gaskets in between, install the fuel main hose to the fuel pressure pulsation damper.
    1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
    Fig 4: Installing Gaskets
    G02998987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL ENGINE WIRE 
    1. Install the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.
  21. INSTALL VACUUM SWITCHING VALVE ASSY 
    1. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 
  22. INSTALL V-VANK COVER BRACKET NO.4 
    1. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) 
  23. INSTALL V-BANK COVER BRACKET NO.3 
    1. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) 
  24. INSTALL V-BANK COVER BRACKET NO.2 
    1. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) 
  25. INSTALL V-BANK COVER BRACKET NO.1 
    1. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) 
  26. INSTALL INTAKE AIR CONNECTOR PIPE 
    1. Install the intake air connector pipe with the bolt and hose clamp.
      1. Torque: 
      2. 4.0 N.m (40 kgf.cm, 35 in..lbf) for hose clamp 
      3. 5.0 N.m (50 kgf.cm, 44 in..lbf) for bolt 
    2. Connect the air hose and ventilation hose No. 1 together.
  27. INSTALL AIR CLEANER INLET NO.1 
  28. INSPECT FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
  29. INSTALL V-BANK COVER 
    1. Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) 
  30. CONNECT BATTERY NEGATIVE TERMINAL 
    NOTE: When disconnecting the negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected (see INITIALIZATION ).
    Fig 5: Identifying Wire Clamp Bracket
    G02998988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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