FUEL INJECTOR (for Direct Injection): Removal

PRECAUTION
CAUTION:
- Do not smoke or be near an open flame when working on the fuel system.
- Keep gasoline away from rubber or leather parts.
- Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.
DISCHARGE FUEL SYSTEM PRESSURE
1. Discharge fuel system pressure (see PRECAUTION ).
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
REMOVE INTAKE MANIFOLD
1. Remove the intake manifold (see REMOVAL ).
REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
1. Remove the fuel pressure pulsation damper assembly (see REMOVAL ).
REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY (See REMOVAL )
REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (See REMOVAL )
REMOVE ENGINE COVER SUB-ASSEMBLY
1. Remove the No. 1, No. 2 and LH No. 2 engine covers.
  
  Fig 1: Identifying Engine Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY
1. Using a 19 mm union nut wrench, remove the fuel pipe.
  
  Fig 2: Removing No. 4 Fuel Pipe Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PCV HOSE
1. Remove the hose from the PCV valve.
  
  Fig 3: Locating PCV Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 FUEL DELIVERY PIPE
1. Disconnect the fuel pressure sensor connector.
  
  Fig 4: Locating Fuel Pressure Sensor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 4 injector connectors.
  
  Fig 5: Locating Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 5 bolts and delivery pipe from the cylinder head.
  NOTE:
  - Make sure that the fuel delivery pipe is disconnected from the delivery pipe (RH side).
  - Be extremely careful not to touch or strike the tips of the injectors.
  - Pull and remove the fuel delivery pipe in a straight line without tilting it.
    
    Fig 6: Locating Fuel Delivery Pipe Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 injector vibration insulators from the cylinder head.
REMOVE FUEL DELIVERY PIPE
1. Disconnect the No. 3 fuel hose.
  
  Fig 7: Identifying No. 3 Fuel Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 4 injector connectors.
  
  Fig 8: Locating Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 5 bolts and delivery pipe from the cylinder head.
  NOTE:
  - Be extremely careful not to touch or strike the tips of the injectors.
  - Pull and remove the fuel delivery pipe in a straight line without tilting it.
4. Remove the 4 injector vibration insulators from the cylinder head.
REMOVE FUEL INJECTOR ASSEMBLY
1. Secure the delivery pipe between aluminum plates in a vise and pull out the injector in a straight line.
  NOTE:
  - Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
  - For reinstallation, attach a tag or label to the injector shaft.
2. Remove the nozzle holder clamp from the injector.
3. Remove the O-ring, backup rings and E-ring from the fuel injector.
REMOVE FUEL INJECTOR SEAL
1. Using the tips of needle-nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.
  NOTE:
  - Excessively pinching the injector seal may damage the groove of the injector.
  - If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
2. Remove the 2 injector seals from the injector.