Fuel Injector ASSY (1ZZ-FE): Replacement

1. Remove the 2 clips and 2 nuts, then remove the cylinder head cover No. 2.
   Fig 1: Removing Cylinder Head Cover No. 2

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1. Disconnect the ventilation hose from the cylinder head cover.
   Fig 2: Disconnecting Ventilation Hose From Cylinder Head Cover

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1. Disconnect the 4 fuel injector connectors.
2. Remove the 3 wire harness clamps from the clamp brackets.
   Fig 3: Disconnecting Fuel Injector Connectors

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3. Remove the fuel pipe clamp No. 1.
4. Disconnect the fuel tube.
5. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
   Fig 4: Removing Fuel Pipe Clamp No. 1

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   NOTE:

   • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
   • Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
   • Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the nylon tube.
   • Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
   • If the fuel tube connector and pipe are stuck, push and pull to release them.
   Fig 5: Cross Section View Of Fuel Tube Connector

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6. Remove the 3 bolts, then remove the fuel delivery pipe together with the fuel injector.
   NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
   Fig 6: Removing Fuel Delivery Pipe Together With Fuel Injector

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7. Remove the 2 delivery pipe spacers from the cylinder head,
8. Remove the 4 insulators from the cylinder head.
   Fig 7: Removing Insulators From Cylinder Head

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1. Pull the 4 fuel injectors out of the fuel delivery pipe.
   Fig 8: Pulling Fuel Injectors Out Of Fuel Delivery Pipe

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1. Apply a light coat of gasoline or spindle oil to a new O-ring, then install it onto each fuel injector.
   Fig 9: Installing O-Ring Onto Fuel Injector (2WD)

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   Fig 10: Installing O-Ring Onto Fuel Injector (4WD)

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2. Apply a light coat of gasoline or spindle oil to the fuel delivery pipe which comes into contact with the O-ring of the fuel injector.
3. Apply a light coat of gasoline or spindle oil to the O-ring again, then install the fuel injector right and left onto the fuel delivery pipe.
   NOTE: Make sure that the O-ring is not cracked or jammed when installing.
   Fig 11: Installing Fuel Injector Onto Fuel Delivery Pipe

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4. Check that the fuel injector rotates smoothly.

If the fuel injector does not rotate, replace the O-ring.

1. Install 4 new insulators into the cylinder head.
2. Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
   NOTE: Make sure that the delivery pipe No. 1 spacer is in the correct direction when installing.
   Fig 12: Installing Delivery Pipe No. 1 Spacers Onto Cylinder Head

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3. Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 3 bolts.
   NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe.
4. Check that the fuel injector rotates smoothly.

   If the fuel injector does not rotate, replace the O-ring.

5. Tighten the 3 bolts to the specified torque,

   Torque: 

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

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

   Fig 13: Installing Fuel Delivery Pipe Together With Fuel Injectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the fuel tube.
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tube to the pipe.
      Fig 14: Installing Fuel Pipe Clamp No. 1

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
   • After connecting the fuel tube, check that the fuel tube is securely connected by pulling the fuel tube connector.
7. Install the fuel pipe clamp No. 1.
8. Install the 3 wire harness clamps.
9. Connect the 4 fuel injector connectors.
   Fig 15: Connecting Fuel Injector Connectors

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1. Connect the ventilation hose to the cylinder head cover.
   NOTE: Make sure that the hose clamp is at the correct angle when installing.
   Fig 16: Connecting Ventilation Hose To Cylinder Head Cover

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Torque: 5.4 N m (55 kgf.cm, 48 In.-.lbf) 

1. Install the cylinder head cover No. 2 with the 2 nuts and 2 clips.
   Fig 17: Installing Cylinder Head Cover No. 2 With Nuts And Clips

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   Torque: 7.0 N. m (70 kgf.cm, 62 in..lbf)