Fuel Injector ASSY (2ZZ-GE): Replacement

WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See FUEL SYSTEM )
REMOVE CYLINDER HEAD COVER No. 2

Fig 1: Removing Cylinder Head Cover No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 3 bolts, nut and cylinder head cover.
REMOVE VENTILATION HOSE No. 2

Fig 2: Removing Ventilation Hose No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the ventilation hose.
REMOVE VENTILATION HOSE

Fig 3: Removing Ventilation Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the ventilation hose.
DISCONNECT ENGINE WIRE

Fig 4: Disconnecting Engine Wire
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the bolt.
2. Disconnect the 4 fuel injector connectors.
3. Disconnect the cam position sensor connector.
REMOVE EFI FUEL PIPE CLAMP

Fig 5: Removing EFI Fuel Pipe Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the EFI fuel pipe clamp.
REMOVE FUEL DELIVERY PIPE SUB-ASSY
1. Disconnect the fuel tube (fuel tube connector) from the fuel pipe.
  
  Fig 6: Disconnecting Fuel Tube (Fuel Tube Connector) From Fuel Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  CAUTION:
  - Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions.
  - As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment.
2. Remove the bolt and clamp.
  
  Fig 7: Removing Bolt & Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors and fuel tube.
  
  Fig 8: Removing Fuel Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
4. Remove the 2 spacers from the cylinder head.
  
  Fig 9: Removing Cylinder Head Spacers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL INJECTOR ASSY

Fig 10: Removing Fuel Injector Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Pull out the 4 fuel injectors from the fuel delivery pipe.
INSTALL FUEL INJECTOR ASSY
1. Install a new insulator to the each fuel injector.
  
  Fig 11: Installing New Insulator & Gasoline To Fuel Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of spindle oil or gasoline to a new O-ring, and install it to the each fuel injector.
  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 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.
INSTALL FUEL DELIVERY PIPE SUB-ASSY

Fig 13: Installing Fuel Delivery Pipe Sub-Assy
Courtesy 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 and fuel tube with the 3 bolts.
  1. Torque:
    1. Bolt A 29 N.m (296 kgf.cm, 21 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.
3. Install the clamp with the bolt.
  1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
4. Connect the fuel tube (fuel tube connector) to the fuel pipe.
CAUTION: Perform connecting operations of the connector (quick type) after observing the precautions.
CONNECT ENGINE WIRE
1. Connect the composition sensor connector.
2. Connect the 4 fuel injector connectors.
3. Install the bolt.
  1. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
INSTALL CYLINDER HEAD COVER No. 2
1. Install the cylinder head cover with the 3 bolts and nut.
  1. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
CHECK FUEL LEAK (See FUEL SYSTEM )