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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 FUEL SYSTEM  ).
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
    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 INTAKE MANIFOLD 
    1. Remove the intake manifold (see REMOVAL ).
  5. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY 
    1. Remove the fuel pressure pulsation damper assembly (see REMOVAL  ).
  6. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL   ) 
  7. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL   ) 
  8. REMOVE ENGINE COVER SUB-ASSEMBLY 
    1. Remove the No. 1, No. 2 and LH No. 2 engine covers.
      Fig 1: Identifying Engine Cover Sub-Assembly
      G04947899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Using SST, remove the fuel pipe.

      SST 09023-12901 

      Fig 2: Removing Fuel Pipe Sub-Assembly
      G04947900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE VENTILATION HOSE 
    1. Remove the ventilation hose from the ventilation valve.
      Fig 3: Locating Ventilation Hose
      G04943739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the fuel pressure sensor connector.
      Fig 4: Locating Fuel Pressure Sensor Connector
      G04947902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 injector connectors.
      Fig 5: Locating Injector Connectors
      G04947903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 5 bolts and delivery pipe from the cylinder head.
      NOTE:
      • Make sure that the fuel delivery pipe is disconnected from the delivery pipe (RH side).
      • 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.
      Fig 6: Locating Delivery Pipe Bolts
      G04947904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 injector vibration insulators from the cylinder head.
  12. REMOVE FUEL DELIVERY PIPE 
    1. Disconnect the No. 3 fuel hose.
      Fig 7: Identifying Fuel Hose
      G04947905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 injector connectors.
      Fig 8: 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.
      Fig 9: Locating Delivery Pipe Bolts
      G04947907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 injector vibration insulators from the cylinder head.
  13. 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's 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 10: Removing Fuel Injector Assembly
    G04947908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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 11: Removing Fuel Injector Seal
    G04947909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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