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FUEL INJECTOR (for Direct Injection): Removal

  1. PRECAUTION 
    CAUTION:
    • Do not smoke or work near an open flame when handling 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 assembly and the fuel injector assembly. 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 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Remove the intake air surge tank assembly (See REMOVAL ).
  5. REMOVE NO. 1 FUEL HOSE  (See REMOVAL )
  6. SEPARATE ENGINE WIRE  (See REMOVAL )
  7. REMOVE NO. 3 COVER SUB-ASSEMBLY  (See REMOVAL )
  8. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (for Direct Injection) 
    1. Remove the fuel pressure pulsation damper assembly and No. 1 fuel pipe sub-assembly (See REMOVAL )
  9. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY  (See REMOVAL )
  10. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY  (See REMOVAL )
  11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Remove the No 1 engine cover sub-assembly
      2. Fig 1: Identifying Engine Cover
      G05749957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH 
    1. Remove the No 2 engine cover sub-assembly LH
      2. Fig 2: Locating Engine Cover LH
      G05749958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 19 mm union nut wrench, remove the No 4 fuel pipe sub- assembly
      2. Fig 3: Removing Fuel Pipe
      G05749959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE SEPARATOR CASE 
    1. Disconnect the fuel pressure sensor connector
      Fig 4: Locating Fuel Pressure Sensor Connector
      G04947902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and separator case from the cylinder head.
      3. Fig 5: Locating Separator Case Bolts
      G04943090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 2 FUEL DELIVERY PIPE (for Direct Injection) 
    1. Disconnect the 4 injector connectors.
      Fig 6: Locating Injector Connectors
      G05749962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and the No 2 fuel delivery pipe from the cylinder head
      NOTE:
      • Be extremely careful not to touch or strike the tips of the injectors.
      • Pull the fuel delivery pipe straight without tilting it.
        • Fig 7: Locating Fuel Delivery Pipe Bolts
        G05749963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 injector vibration insulators from the cylinder head.
      4. Fig 8: Locating Injector Vibration Insulators
      G05749964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL DELIVERY PIPE (for Direct Injection) 
    1. Disconnect the 4 injector connectors
      Fig 9: Locating Injector Connectors
      G05749965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and the fuel delivery pipe from the cylinder head.
      NOTE:
      • Be extremely careful not to touch or strike the tips of the injectors.
      • Pull the fuel delivery pipe straight without tilting it.
        • Fig 10: Locating Fuel Delivery Pipe Bolts
        G05749966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 injector vibration insulators from the cylinder head
      4. Fig 11: Locating Injector Vibration Insulators
      G05749967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection) 
    1. Secure the delivery pipe between aluminum plates in a vise and pull the fuel injector assembly out in a straight line.
      NOTE:
      • Pull the fuel injector assembly straight out to avoid damage to the seal surface of the fuel delivery pipe and No. 2 fuel delivery pipe O-ring.
      • For reinstallation, attach a tag or label to the injector shaft.
        • Fig 12: Identifying Fuel Injector Assembly (For Direct Injection)
        G04947908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nozzle holder clamp from the fuel injector assembly
    3. Remove the O-ring, backup rings (No. 1, No. 2 and No. 3) and E-ring from the fuel injector
      4. Fig 13: Removing Nozzle Holder Clamp From Fuel Injector Assembly
      G05749969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL INJECTOR SEAL 
    1. Using the tips of needle-nose pliers, pinch and pull one of the 2 fuel injector seals at several points to stretch it Repeat this for the other fuel injector seal
      NOTE:
      • Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.
      • If an injector is dropped or the tip of an fuel injector assembly is struck, replace it with a new one.
    2. Remove the 2 injector seals from the fuel injector assembly
      3. Fig 14: Removing Fuel Injector Seal
      G04947909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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