Fuel Injector Assembly: Replacement

1. Remove the 2 bolts and the cowl top to cowl brace inner No. 1.

Fig 1: Removing Bolts And Cowl Top To Cowl Brace Inner

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1. Remove the wire harness clamp.
2. Remove the grommet.
3. Remove the 7 bolts and the cowl top panel outer front.

Fig 2: Removing Bolts And Cowl Top Panel Outer Front

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1. Disconnect the 2 VSV connectors.
2. Remove the wire harness clamp.
   Fig 3: Removing Wire Harness Clamp

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3. Disconnect the fuel vapor feed hose.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 2 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts and the emission control valve set.

Fig 4: Removing Nuts Of Emission Control Valve Set

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1. Disconnect throttle motor connector.
2. Disconnect the water by-pass hose No. 3.
3. Disconnect the water by-pass hose No. 2.
4. Disconnect the union to check valve hose.
   Fig 5: Disconnecting Hose

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5. Disconnect the ventilation hose.
   Fig 6: Disconnecting Ventilation Hose

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6. Remove the 2 set nuts of the pressure feed tube.
   Fig 7: Removing Set Nuts Of Pressure Feed Tube

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7. Remove the 2 bolts and the engine hunger No. 1.
8. Remove the 2 bolts and the surge tank stay No. 1.
9. Remove the 2 bolts and the surge tank stay No. 2.
   Fig 8: Removing Bolts And Surge Tank Stay

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10. Using a socket hexagon wrench 8, remove the 4 bolts.
11. Remove the 2 nuts, the emission control valve bracket and the intake air surge tank.
Fig 9: Removing Intake Air Surge Tank
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12. Remove the gasket from the intake air surge tank.

1. Remove the bolt and the fuel pipe No. 1.
2. Remove the fuel pressure pulsation damper and the 2 gaskets.
3. Remove the fuel pipe No. 2 union bolt and the 2 gaskets.

Fig 10: Removing Fuel Pipe Union Bolt And Gaskets

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1. Disconnect the 6 fuel injector connectors.
   Fig 11: Disconnecting Fuel Injector Connectors

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2. Remove the 4 bolts and the 2 fuel delivery pipes together with the 6 fuel injectors.
   NOTE: Be careful not to drop the fuel injectors when removing the delivery pipe.
   Fig 12: Removing Bolts Of Fuel Delivery Pipes

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3. Remove the 4 delivery pipe No. 1 spacers (*1) and the 6 insulators (*2) from the intake manifold.
   Fig 13: Removing Delivery Pipe Spacers And Insulators From Intake Manifold

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4. Pull out the fuel injector from the fuel delivery pipe.

Fig 14: Pulling Out Fuel Injector From Fuel Delivery Pipe

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1. Install new grommets to the each fuel injector.
2. Apply a light coat of spindle oil or gasoline to new O-rings, and install it to the each fuel injector.
   Fig 15: Installing New Grommets To Each Fuel Injector

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3. Apply a light coat of spindle oil or gasoline on the place where the fuel delivery pipe contacts the O-ring.
4. Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
   Fig 16: Installing Fuel Delivery Pipe

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   NOTE:

   • Be careful not to twist the O-ring.
   • After installing the fuel injectors, check that they turns smoothly. If not, reinstall it with a new O-ring.
5. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
6. Place the 2 fuel delivery pipes and 6 fuel injectors together to the intake manifold.
   Fig 17: Installing Fuel Injectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
7. Temporarily install 4 bolts which are used to attach the fuel delivery pipe to the intake manifold.
8. Check that the fuel injectors rotate smoothly.

   If fuel injectors do not rotate smoothly, the probable cause is incorrect installation of O-ring. Replace with the O-ring.

9. Tighten the 4 bolts.

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

10. Connect the 6 fuel injector connectors.

1. Install 2 new gaskets and the fuel pipe No. 2 union bolt.

   Torque: 33 N.m (331 kgf.cm, 24 ft.lbf) 

2. Install 2 new gaskets and the fuel pressure pulsation damper.

   Torque: 33 N.m (331 kgf.cm, 24 ft.lbf) 

3. Install the fuel pipe No. 1 with the bolt.

   Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

1. Install a new gasket to the intake air surge tank.
2. Install the intake air surge tank and the emission control valve bracket with the 2 nuts.

   Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

3. Using a socket hexagon wrench 8, tighten the 4 bolts.

   Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

4. Install the surge tank stay No. 2 with the 2 bolts.

   Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

5. Install the surge tank stay No. 1 with the 2 bolts.

   Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

6. Install the engine hunger No. 1 with the 2 bolts.

   Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

7. Install the pressure feed tube with the 2 nuts.

   Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 

8. Connect the ventilation hose.
9. Connect the union to check valve hose.
10. Connect the water by-pass hose No. 2.
11. Connect the water by-pass hose No. 3.
12. Connect the throttle motor connector.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)