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Fuel Injector ASSY: Replacement

  1. Work for preventing gasoline from spilling out. See step  2.
  2. Drain coolant. See REPLACEMENT .
  3. Remove v-bank cover sub-assy.
  4. Remove battery.
  5. Remove air cleaner assembly with hose (See REMOVAL & INSTALLATION & DISASSEMBLY & REASSEMBLY ).
  6. Remove front suspension upper brace center (w/front suspension brace upper center).
  7. Remove intake air surge tank.

    See page VALVE CLEARANCE .

  8. Separate fuel pipe sub-assy No. 1
    1. Remove the pulsation damper and 2 gaskets.
    2. Remove the bolt and 2 gaskets.
    3. Remove the bolt and disconnect the fuel pipe sub-assembly No. 1 from the intake manifold.
    Fig 1: Separating Fuel Pipe Sub-Assy No. 1
    G01207119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Remove fuel injector assy
    1. Disconnect the injector connectors.
    2. Remove the 2 bolts and fuel delivery pipe, while pulling out both ends of the fuel delivery pipe equally.
    3. While turning the injector clockwise and counterclockwise, pull out the injector from the delivery pipe.
  10. Install fuel injector assy.
    1. Apply a light coat of gasoline to a new O-ring and install them to each injectors.
    2. While turning the injector clockwise and counterclockwise, install it to the delivery pipe.
    3. Check that the injectors rotate smoothly.
      NOTE: If injectors do not rotate smoothly, the probable cause is incorrect installation of the O-rings. Replace new o-rings.
    4. Install the delivery pipe with the injectors.

      Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      NOTE:
      • Be careful not to drop the injectors when installing the delivery pipe.
      • Check that the injectors rotate smoothly after installing the delivery pipe.
    Fig 2: Installing Fuel Injector Assy
    G01207120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. Install fuel pipe sub-assy No. 1
    1. Install the fuel pipe No. 1 with the 2 new pulsation damper gaskets and the pulsation damper.

      Torque: 33 N.m (336 kgf.cm, 24 ft.lbf) 

    2. Install the delivery pipe with 2 new fuel pipe No. 1 gaskets and a bolt to the fuel pipe No. 1.

      Torque: 33 N.m (336 kgf.cm, 24 ft.lbf) 

    3. Install the fuel pipe No. 1 to the intake manifold with a bolt.

      Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

  12. Install intake air surge tank (See VALVE CLEARANCE ).
  13. Install front suspension upper brace center (w/front suspension brace upper center).

    Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) 

  14. Install air cleaner assembly with hose. See REMOVAL & INSTALLATION & DISASSEMBLY & REASSEMBLY .
    Fig 3: Installing Fuel Pipe Sub-Assy No. 1
    G01207121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Install V-bank cover sub-assy.
  16. Add coolant. See COOLING FAN SYSTEM .
  17. Check engine coolant leak. See REPLACEMENT .
  18. Inspect fuel leak.
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