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Fuel Injector ASSY: Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  FUEL SYSTEM  ) 
  2. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 2 nuts, 2 clips and cylinder head cover.
    Fig 1: Removing Cylinder Head Cover No. 2
    G02898692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. DISCONNECT VENTILATION HOSE 
    1. Disconnect the ventilation hose from the cylinder head cover.
    Fig 2: Disconnecting Ventilation Hose From Cylinder Head Cover
    G02898693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCONNECT ENGINE WIRE 
    1. Disconnect the 4 fuel injector connectors.
    2. Remove the 3 wire harness clamps from the clamp brackets.
    Fig 3: Disconnecting Fuel Injector Connectors
    G02898694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE EFI FUEL PIPE CLAMP 
    1. Remove the EFI fuel pipe clamp.
    Fig 4: Removing EFI Fuel Pipe Clamp
    G02898695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. DISCONNECT FUEL TUBE SUB-ASSY 
    1. Using a SST, disconnect the fuel tube.

      SST 09268-21010

      1. Assemble the SST to the connection as shown.
      2. Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector.
      3. Slide the SST and the connector together towards the fuel tube assembly.
      NOTE:
      • Check if there is dirt mud on the pipe and around the connector before disconnecting them and clean the dirt away.
      • Do not bent, fold and rotate the nylon tube.
      • When the connector and the pipe are stuck, push and pull the connector to free to disconnect and pull it out.
      • Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
    Fig 5: Inserting SST
    G02898696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Identifying Structure Of Metallic Connector
    G02898697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL DELIVERY PIPE SUB-ASSY 
    1. Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors.
      NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
      Fig 7: Removing Fuel Delivery Pipe Together With Fuel Injectors
      G02898698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 spacers from the cylinder head.
    Fig 8: Removing Spacers From Cylinder Head
    G02898699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL INJECTOR ASSY 
    1. Pull out the 4 fuel injectors from the fuel delivery pipe.
    Fig 9: Removing Fuel Injectors From Fuel Delivery Pipe
    G02898700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL INJECTOR ASSY 
    1. Install a new insulator to the each fuel injector.
    2. Apply a light coat of spindle oil or gasoline to a new CD-ring, and install it to the each fuel injector.
      NOTE: Never use engine, gear or brake oil.
      Fig 10: Identifying Insulator
      G02898701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a light coat of spindle oil or gasoline on the place where the fuel delivery pipe touches on the O-ring.
    4. While turning the fuel injector clockwise and counterclockwise, and push it to the fuel delivery pipe.
    NOTE:
    • Be careful not twist the O-ring.
    • After installing the fuel injectors, Check that they turns smoothly. If the fuel injector does not, reinstall it with a new O-ring.
    Fig 11: Installing New Insulator To Fuel Injector
    G02898702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FUEL DELIVERY PIPE SUB-ASSY 
    1. Install the 2 spacers to the cylinder head.
    2. Install the fuel delivery pipe together with the 4 fuel injectors with the 3 bolts.

      Torque: 

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

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

    NOTE:
    • Be careful not drop the fuel injectors when installing the fuel delivery pipe.
    • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.
    Fig 12: Installing Fuel Delivery Pipe Together With Fuel Injectors With Bolts
    G02898703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT FUEL TUBE SUB-ASSY 
    1. Connect the fuel tube to the fuel delivery pipe.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part of the fuel tube.
    • After connecting, check if the fuel tube and the connector are securely connected by pulling them.
  12. INSTALL CYLINDER HEAD COVER NO. 2 
    1. Install the cylinder head cover with the 2 nuts and 2 clips.

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

  13. CHECK FUEL LEAK (See  FUEL SYSTEM  ) 
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