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FUEL INJECTOR (for Direct Injection): Removal

  1. 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.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (see PRECAUTION  ).
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    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.
  4. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY 
    1. Remove the fuel pressure pulsation damper (see REMOVAL  ).
  5. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL   ) 
  6. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL   ) 
  7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    8. Fig 1: Identifying No. 1 Engine Cover Sub-Assembly
    G05772886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY 
    Fig 2: Identifying No. 2 Engine Cover Sub-Assembly
    G05772920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH 
    Fig 3: Identifying No. 2 Engine Cover Sub-Assembly LH
    G05772888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 19 mm union nut wrench, remove the fuel pipe.
      Fig 4: Removing Fuel Pipe
      G05749959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE PCV HOSE 
    1. Remove the hose from the PCV valve.
      Fig 5: Locating Hose And PCV Valve
      G04943739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the fuel pressure sensor connector.
      Fig 6: Locating Fuel Pressure Sensor Connector
      G04947902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 injector connectors.
      Fig 7: Locating Injector Connectors
      G04947903Courtesy 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.
      Fig 8: Locating Delivery Pipe Bolts
      G04947904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL DELIVERY PIPE 
    1. Disconnect the No. 3 fuel hose.
      Fig 9: Locating No. 3 Fuel Hose
      G04947905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 injector connectors.
      Fig 10: Locating Injector Connectors
      G04947906Courtesy 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.
      Fig 11: Locating Delivery Pipe Bolts
      G04947907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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 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.
      Fig 12: Identifying Tag Or Label Of Injector Shaft
      G04947908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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.
      Fig 13: Removing Fuel Injector Seal
      G04947909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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