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Fuel Injector ASSY: Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  FUEL SYSTEM   ) 
  2. DRAIN COOLANT (See  COOLANT  ) 
  3. REMOVE V-BANK COVER SUB-ASSY (See  PARTIAL ENGINE ASSY  ) 
  4. REMOVE BATTERY 
  5. REMOVE AIR CLEANER ASSEMBLY WITH HOSE 
  6. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/FRONT SUSPENSION BRACE UPPER CENTER) 
  7. REMOVE INTAKE AIR SURGE TANK (See  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: Removing Pulsation Damper And Gaskets
    G01328015Courtesy 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.
      1. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 
      Fig 2: Applying A Light Coat Of Gasoline To A New O-Ring
      G01328016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to drop the injectors when installing the delivery pipe.
      • Check that the injectors rotate smoothly after installing the delivery pipe.
  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.
      1. 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.
      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.
      1. Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 
      Fig 3: Installing Fuel Pipe No.1 With New Pulsation Damper Gaskets
      G01328017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL INTAKE AIR SURGE TANK (See  VALVE CLEARANCE  ) 
  13. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) 
    1. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) 
  14. INSTALL AIR CLEANER ASSEMBLY WITH HOSE  
  15. INSTALL V-BANK COVER SUB-ASSY (See  PARTIAL ENGINE ASSY  ) 
  16. ADD COOLANT (See  COOLANT  ) 
  17. CHECK ENGINE COOLANT LEAK (See  COOLANT  ) 
  18. INSPECT FUEL LEAK 
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