LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Toyota >> 2004 >> Matrix Base, 4WD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System >> Fuel Injector ASSY (1ZZ-FE) >> Replacement
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Fuel Injector ASSY (1ZZ-FE): 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 Nuts & Clips
    G00922731Courtesy 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
    G00922732Courtesy 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: Identifying Fuel Injector Connectors & Harness Clamp Brackets
    G00922733Courtesy 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
    G00922734Courtesy 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 in Fig 5.
        Fig 5: Assembling SST To Connection
        G00922735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 6: Identifying Structure Of Metallic Connector
    G00922736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL DELIVERY PIPE SUB-ASSY 
    Fig 7: Removing Fuel Delivery Pipe Sub-Assy
    G00922737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    2. Remove the 2 spacers from the cylinder head.
    Fig 8: Removing Spacers
    G00922738Courtesy 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 Injector Assy
    G00922739Courtesy 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 O-ring, and install it to the each fuel injector.
      Fig 10: Applying Light Coat Of Gasoline In Fuel Injector
      G00922740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Never use engine, gear or brake oil.
    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.
      5. Fig 11: Turning Fuel Injector Clockwise & Counterclockwise
      G00922741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  10. INSTALL FUEL DELIVERY PIPE SUB-ASSY 
    Fig 12: Installing Fuel Delivery Pipe
    G00922742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      1. Torque: 
        1. Bolt A 19 N.m (194 kgf.cm, 14 ft.lbf) 
        2. 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.
  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.
      1. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 
  13. CHECK FUEL LEAK (See   FUEL SYSTEM   ) 
scientia non olet · About LEMON Manuals