Fuel Injector: Removal

DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
- Even after discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
1. Disconnect the cable from the negative (-) battery terminal.
  NOTE: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. Disconnect the fuel pump connector.
  
  Fig 1: Disconnecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the cable to the negative (-) battery terminal.
4. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
  HINT:
  
  DTC P0171/0174 (system too lean) may be set.
5. Crank the engine again, then check that the engine does not start.
6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
7. Connect the fuel pump connector.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
REMOVE V-BANK COVER (See REMOVAL )
REMOVE INTAKE AIR CONNECTOR (See REMOVAL )
REMOVE FUEL PRESSURE PULSATION DAMPER
1. Remove the pulsation damper, upper gasket, fuel main hose and lower gasket.
  NOTE:
  - Put a cloth or equivalent under the delivery pipe.
  - Slowly loosen the pulsation damper.
  Fig 2: Removing Fuel Pressure Pulsation Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT VENTILATION HOSE
1. Disconnect the ventilation hose from the ventilation valve.
DISCONNECT PURGE VSV
1. Disconnect the purge VSV connector.
2. Disconnect the purge line hose from the purge VSV.
3. Remove the bolt and disconnect the VSV from the intake manifold.
  
  Fig 3: Disconnecting Purge VSV
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT ENGINE WIRE
1. Disconnect the engine wire clamps from the No. 1 engine hanger and engine wire bracket.
2. Disconnect the 2 wire clamps on the engine wire from the brackets on the delivery pipe RH.
  
  Fig 4: Disconnecting Engine Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL RETURN PIPE
1. Remove the fuel pipe clamp.
  
  Fig 5: Removing Fuel Pipe Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check for dirt or mud on the pipe and around the connector before disconnecting them. Clean if necessary.
3. Disconnect the connector them by hand.
  If the connector and the pipe are stuck, pinch the connector, push and pull the pipe to disconnect it and pull it out.
  
  NOTE: Do not use any tools.
  
  Fig 6: Disconnecting Connector By Hand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
5. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
  
  Fig 7: Covering Fuel Return Pipe Connector With Plastic Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 3 bolts and fuel return pipe from the fuel pressure regulator.
  HINT:
  
  Move it aside to secure more work space.
  
  Fig 8: Removing Fuel Return Pipe From Fuel Pressure Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DELIVERY PIPE AND INJECTOR
NOTE:
- Be careful not to drop the injectors when removing the delivery pipes.
- Do not apply any load to the injector in horizontal direction.
1. Remove the bolt, 2 union bolts, 4 gaskets and front fuel pipe.
2. Disconnect the 8 injector connectors.
3. Remove the 4 nuts holding the delivery pipes to the lower intake manifold.
4. Remove the 2 delivery pipes, 8 injectors, and 8 insulators.
5. Remove the O-ring and grommet from each injector.
Fig 9: Removing Delivery Pipe & Injector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002