Fuel Injector ASSY (3MZ-FE): Replacement

DISCHARGE FUEL SYSTEM PRESSURE (See FUEL SYSTEM (3MZ-FE) )
DRAIN ENGINE COOLANT (See REPLACEMENT )
REMOVE FR WIPER ARM LH (See WINDSHIELD WIPER MOTOR ASSY )
REMOVE FR WIPER ARM RH (See WINDSHIELD WIPER MOTOR ASSY )
REMOVE FRONT FENDER TO COWL SIDE SEAL LH
REMOVE FRONT FENDER TO COWL SIDE SEAL RH
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See WINDSHIELD WIPER MOTOR ASSY )
REMOVE WINDSHIELD WIPER LINK ASSY (See WINDSHIELD WIPER MOTOR ASSY )
REMOVE COWL TOP PANEL SUB-ASSY OUTER
1. Disconnect the rain sensor connector. (w/Auto Wiper)
2. Remove the 2 wire harness clamps.
3. Remove the grommet.
4. Remove the 6 nuts, and then remove 2 front shock absorber caps. (w/Air Suspension)
5. Remove the 4 set nuts of the shock absorber. (w/o Air Suspension)
6. Remove the 4 bolts and 2 nuts, and then remove the cowl top panel outer.
7. Tighten the 6 set nuts of the shock absorber.
  Torque: 80 N.m (815 kgf.cm, 59 ft.lbf)
  
  Fig 1: Removing Cowl Top Panel Sub-Assy Outer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE V-BANK COVER SUB-ASSY (See REPLACEMENT )
REMOVE AIR CLEANER CAP SUB-ASSY
1. Disconnect the mass air flow meter connector.
2. Disconnect the 4 vacuum hoses.
3. Disconnect the ventilation hose No. 2.
4. Remove the fuel vapor feed hose from the 2 hose clamps.
5. Loosen the 2 air cleaner cap bolts.
6. Loosen the air cleaner hose clamp bolt, and remove the air cleaner cap.
7. Remove the air cleaner filter element.
  
  Fig 2: Removing Air Cleaner Cap Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EMISSION CONTROL VALVE SET
1. Disconnect the 2 VSV connectors.
2. Remove the wire harness clamp.
  
  Fig 3: Removing Emission Control Valve Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the fuel vapor feed hose No. 1.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 2 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts, and then remove the emission control valve set.
  
  Fig 4: Removing Vacuum And Vapor Feed Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE AIR SURGE TANK
1. Disconnect the throttle motor connector.
2. Disconnect the water by-pass hose No. 3.
3. Disconnect the water by-pass hose No. 2.
4. Disconnect the union to check valve hose.
  
  Fig 5: Removing Throttle Motor Connector And Water By-Pass Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the ventilation hose.
  
  Fig 6: Removing Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 3 nuts and separate the pressure feed tube.
  
  Fig 7: Removing Pressure Feed Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 2 bolts, and then remove the engine hunger No. 1.
8. Remove the 2 bolts, and then remove the surge tank stay No. 1.
9. Remove the 2 bolts, and then remove the surge tank stay No. 2.
  
  Fig 8: Removing Engine Hunger And Surge Tank Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a socket hexagon wrench 8, remove the 4 bolts.
11. Remove the 2 nuts, and then remove the emission control valve bracket and the intake air surge tank.
12. Remove the gasket from the intake air surge tank.
  
  Fig 9: Removing Emission Control Valve Bracket & Intake Air Surge Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FUEL PIPE SUB-ASSY NO. 1
1. Remove the bolt and separate the fuel pipe No. 1.
2. Remove the fuel pressure pulsation damper and the 2 gaskets.
3. Remove the fuel pipe No. 2 union bolt and the 2 gaskets.
  
  Fig 10: Separating Fuel Pipe Sub-Assy No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL INJECTOR ASSY
1. Disconnect the 6 fuel injector connectors.
  
  Fig 11: Disconnecting Fuel Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts, and then remove the 2 fuel delivery pipes together with the 6 fuel injectors.
  NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
  
  Fig 12: Removing Fuel Delivery Pipes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 4 delivery pipe No. 1 spacers (*1) and the 6 insulators (*2) from the intake manifold.
  
  Fig 13: Removing Insulators From Intake Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Pull out the fuel injector from the fuel delivery pipe.
  
  Fig 14: Removing Fuel Injector From Fuel Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL INJECTOR ASSY
1. Install new grommets to each fuel injector.
2. Apply a light coat of spindle oil or gasoline to new O-rings, and install them to each fuel injector.
  
  Fig 15: Installing New Grommets To Fuel Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply a light coat of spindle oil or gasoline on the place where the fuel delivery pipe contacts the O-ring.
4. Push the fuel injector while twisting it back and force to install it in the fuel delivery pipe.
  
  Fig 16: Installing Fuel Injector In Fuel Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to twist the O-ring.
  - After installing the fuel injector, check that they turns smoothly. If not, reinstall it with a new O-ring.
5. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
6. Place the 2 fuel delivery pipes and the 6 fuel injectors together to the intake manifold.
  
  Fig 17: Installing Fuel Delivery Pipes And Fuel Injectors Together To Intake Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
7. Temporarily install 4 bolts which are used to attach the fuel delivery pipe to the intake manifold.
8. Check that the fuel injectors rotate smoothly.
  If fuel injectors do not rotate smoothly, the probable cause is incorrect installation of O-ring. Replace with the O-ring.
9. Tighten the 4 bolts.
  Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
10. Connect the 6 fuel injector connectors.
INSTALL FUEL PIPE SUB-ASSY NO. 1
1. Install 2 new gaskets and the fuel pipe No. 2 union bolt.
  Torque: 33 N.m (331 kgf.cm, 24 ft.lbf)
2. Install 2 new gaskets and the fuel pressure pulsation damper.
  Torque: 33 N.m (331 kgf.cm, 24 ft.lbf)
3. Install the fuel pipe No. 1 with the bolt.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
INSTALL INTAKE AIR SURGE TANK
1. Install a new gasket to the intake air surge tank.
2. Install the intake air surge tank and the emission control valve bracket with the 2 nuts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
3. Using a socket hexagon wrench 8, tighten the 4 bolts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
4. Install the surge tank stay No. 2 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
5. Install the surge tank stay No. 1 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
6. Install the engine hunger No. 1 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
7. Install the pressure feed tube with the 3 nuts.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
8. Connect the ventilation hose.
9. Connect the union to check valve hose.
10. Connect the water by-pass hose No. 2.
11. Connect the water by-pass hose No. 3.
12. Connect the throttle motor connector.
INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
CHECK CONNECTION OF VACUUM HOSE (See REPLACEMENT )
ADD ENGINE COOLANT (See REPLACEMENT )
CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )
CHECK FOR FUEL LEAKS (See ON-VEHICLE INSPECTION )
INSTALL V-BANK COVER SUB-ASSY (See REPLACEMENT )
INSTALL COWL TOP PANEL SUB-ASSY OUTER
Torque:

5.0 N.m (51 kgf.cm, 44 in.lbf) (Set bolts and nuts of the cowl top panel outer)

80 N.m (815 kgf.cm, 59 ft.lbf) (Set nuts of the shock absorber)
INSTALL WINDSHIELD WIPER LINK ASSY (See WINDSHIELD WIPER MOTOR ASSY )
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY
INSTALL FRONT FENDER TO COWL SIDE SEAL RH
INSTALL FRONT FENDER TO COWL SIDE SEAL LH
INSTALL FR WIPER ARM RH (See WINDSHIELD WIPER MOTOR ASSY )
INSTALL FR WIPER ARM LH (See WINDSHIELD WIPER MOTOR ASSY )