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Fuel Injector ASSY: Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION  ) 
  2. REMOVE V-BANK COVER 
    1. Remove the V-bank cover by removing the 2 nuts.
  3. REMOVE AIR CLEANER INLET NO.1 
  4. REMOVE INTAKE AIR CONNECTOR PIPE 
    1. Disconnect the air hose and ventilation hose No.1.
    2. Remove the intake air connector pipe by removing the bolt and hose clamp.
  5. REMOVE V-BANK COVER BRACKET NO.1 
  6. REMOVE V-BANK COVER BRACKET NO.2 
  7. REMOVE V-BANK COVER BRACKET NO.3 
  8. REMOVE V-VANK COVER BRACKET NO.4 
  9. REMOVE VACUUM SWITCHING VALVE ASSY 
  10. REMOVE ENGINE WIRE 
    1. Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe.
      Fig 1: Identifying 2 Wire Clamps On Wire Clamp Bracket
      G01051860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Disconnect the fuel delivery pipe and the fuel pipe by removing both right and left pulsation dampers.
    2. Remove the gasket.
  12. 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. Then remove the fuel delivery pipe No.1 by pulling it straight upward holding both the ends.
      Fig 2: Identifying Water By-Pass Pipe No.1 And No.2 Removing Bolts
      G01051861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL DELIVERY PIPE SUB-ASSY NO.2 
    1. Disconnect the connector.
    2. Remove the 2 bolts, then the fuel delivery pipe No.2 by pulling it straight upward holding both the ends.
  14. 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 New Grommet And Vibration Insulator To Injector
    G01051862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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.
  16. 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) by the 2 nuts.

      Torque: 21 N.m (214 kgf.cm, 15.5 ft.lbf) 

  17. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Inserting 2 new gaskets in between, install the fuel main hose to the fuel pressure pulsation damper.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

      Fig 4: Installing Fuel Pressure Pulsation Damper Assy
      G01051863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL ENGINE WIRE 
    1. Connect the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.
      Fig 5: Connecting 2 Wire Clamps To Wire Clamp Bracket
      G01051864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL VACUUM SWITCHING VALVE ASSY 

    Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

  20. INSTALL V-VANK COVER BRACKET NO.4 

    Torque: 7.5 N.m (76.5 kgf.cm, 66 in. lbf) 

  21. INSTALL V-BANK COVER BRACKET NO.3 

    Torque: 7.5 N.m (76.5 kgf.cm, 66 in.lbf) 

    INSTALL V-BANK COVER BRACKET NO.2 

    Torque: 7.5 N.m (76.5 kgf.cm, 66 in.lbf) 

  22. INSTALL V-BANK COVER BRACKET NO.1 

    Torque: 7.5 N.m (76.5 kgf.cm, 66 in. lbf) 

  23. INSTALL INTAKE AIR CONNECTOR PIPE 
    1. Install the intake air connector pipe with the bolt and the hose clamp.

      Torque: 

      4.0 N.m (40 kgf.cm, 35 in. lbf) for hose clamp 

      5.0 N.m (50 kgf.cm, 44 in. lbf) for bolt 

    2. Connect the air hose and the ventilation hose No.1 together.
  24. INSTALL AIR CLEANER INLET NO.1 
  25. INSPECT FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  26. INSTALL V-BANK COVER 

    Torque: 5.0 N.m (51kgf.cm, 44 in. lbf) 

  27. POWER WINDOW CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
  28. FRONT POWER SEAT CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
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