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Fuel Injector ASSY: Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM   ) 
  2. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 4 nuts and cylinder head cover.
      Fig 1: Removing Cylinder Head Cover
      G00759311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE IGNITION COIL NO. 1 
    1. Disconnect the 4 ignition coil connectors.
    2. Remove the 4 bolts and 4 ignition coils.
      Fig 2: Removing Ignition Coil
      G00759312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CYLINDER HEAD COVER SUB-ASSY 
    1. Disconnect the ventilation hose No. 2.
    2. Disconnect the ventilation hose.
      Fig 3: Disconnecting Ventilation Hose
      G00759313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 9 bolts, 2 nuts, 2 seal washers and then remove the cylinder head cover.
      Fig 4: Removing Cylinder Head Cover
      G00759314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT FUEL TUBE SUB-ASSY 
    1. Remove the fuel pipe clamp.
    2. Using SST, disconnect the fuel tube.

      SST 09268-21010

      1. Assemble SST to the connection of the fuel tube as shown in the illustration.
      2. Turn SST, align the retainers inside the connector with SST chamfered parts and insert the SST into the connector.
      3. Push in SST and the connector together towards the fuel tube assembly.
    Fig 5: Disconnecting Fuel Tube
    G00759315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Check the pipe and around the connector for dirt or mud before disconnecting them and remove the dirt as necessary.
    • Do not bent and twist the nylon tube.
    • When the connector and pipe are stuck, push and pull the connector to release and disconnect and pull it out.
    • Prevent the disconnected pipe and connector from being damaged and foreign objects being introduced by covering them with a vinyl or plastic bag.
    Fig 6: Covering Pipe And Connector
    G00759316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL DELIVERY PIPE SUB-ASSY 
    1. Disconnect the 4 fuel injector connectors.
    2. Remove the 3 bolts and then remove the fuel delivery pipe with the 4 fuel injectors.
      NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
    3. Remove the 2 spacers from the cylinder head.
      Fig 7: Removing Fuel Delivery Pipe Sub-Assy
      G00759317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL INJECTOR ASSY 
    1. Pull out the 4 fuel injectors.
      Fig 8: Removing Fuel Injector Assy
      G00759318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FUEL INJECTOR ASSY 
    1. Install new insulators to each fuel injector.
    2. Apply a light coat of grease or gasoline to new O-rings and install them to each fuel injector.
      Fig 9: Installing Insulator And O-Ring To Injector
      G00759319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a light coat of grease or gasoline on the place where a fuel delivery pipe contacts the O-ring.
    4. While turning the fuel injector clockwise and counter-clockwise, push it to the fuel delivery pipe.
    NOTE:
    • Be careful not to twist the O-ring.
    • After installing the fuel injectors, check that they turn smoothly. If not, replace it with a new O-ring.
    Fig 10: Installing Fuel Injector Assy
    G00759320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL DELIVERY PIPE SUB-ASSY 
    1. Install the 2 spacers to the cylinder head.
    2. Install the fuel delivery pipe and 4 fuel injectors together.

      Torque: 

      19 N.m (194 kgf.cm, 14 ft..lbf) for bolt A 

      9.0 N.m (92 kgf.cm, 80 in..lbf) for bolt B 

      NOTE:
      • Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
      • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.
    3. Connect the 4 fuel injector connectors.
      Fig 11: Install Fuel Delivery Pipe Sub-Assy
      G00759321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT FUEL TUBE SUB-ASSY 
    1. Connect the fuel tube.
      NOTE:
      • Check the connected parts of the pipe for damage or foreign objects.
      • After finishing the connection, check if the pipe and connector are securely connected by pulling on them.
    2. Install the fuel pipe clamp.
  11. INSTALL CYLINDER HEAD COVER SUB-ASSY 
    1. Apply seal packing to the 2 locations as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover within 3 minutes after applying seal packing.
      • Do not start engine within 2 hours of installation.
      Fig 12: Applying Seal Packing
      G00759322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cylinder head cover with the 9 bolts, 2 nuts and 2 seal washers.
    3. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

      Torque: 10 N.m (102 kgf.cm, 7 ft..lbf) 

    4. Connect the ventilation hose.
    5. Connect the ventilation hose No. 2.
      Fig 13: Tightening Sequence Of Cylinder Head Cover Bolts
      G00759323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL IGNITION COIL NO. 1 
    1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 
  13. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
  14. INSTALL CYLINDER HEAD COVER NO. 2 
    1. Install the cylinder head cover.
    2. First tighten nut A, then tighten nut B.

    Torque: 7.0 N.m (71 kgf.cm, 62 in. lbf) 

    Fig 14: Installing Cylinder Head Cover
    G00759324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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