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Fuel Injector: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See PRECAUTION  .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE NO. 1 ENGINE UNDER COVER 
  4. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  5. REMOVE FRONT WIPER ARM HEAD CAP  (See REMOVAL )
  6. REMOVE FRONT WIPER ARM RH  (See REMOVAL )
  7. REMOVE FRONT WIPER ARM LH  (See REMOVAL )
  8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  10. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER 
    1. Remove the 2 bolts and the No. 1 cowl top to cowl brace inner.
      Fig 1: Locating Cowl Top And Bolts
      G05138172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT 
    1. Remove the wire harness clamp.
    2. Disconnect the fuel pump resistor connector.
    3. Remove the 7 bolts and the cowl top panel outer front.
    Fig 2: Locating Wire Harness Clamp
    G05138173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE V-BANK COVER SUB-ASSEMBLY  (See REMOVAL )
  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 
    1. Disconnect the 3 vacuum hoses.
      Fig 3: Locating Vacuum Hoses
      G05136358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 ventilation hose and air cleaner hose band.
    3. Disconnect the vacuum hose (EVAP) from the air cleaner hose.
      Fig 4: Locating Vacuum Hose (EVAP) And Air Cleaner Hose
      G05136359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and air cleaner cap sub-assembly.
      Fig 5: Locating Air Cleaner Cap Sub-Assembly And Bolts
      G05138176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly. (*1)
    2. Disconnect the fuel vapor feed hose assembly.(*2)
    3. Disconnect the throttle with motor body assembly connector and clamp. (*3)
      Fig 6: Locating Intake Air Surge Tank Assembly
      G05138177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the No. 1 ventilation hose. (*4)
    5. Disconnect the union to check valve hose. (*5)
      Fig 7: Locating Valve Hose And Union
      G05138178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the connector.
      Fig 8: Locating Connector
      G04974478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a 5 mm socket hexagon wrench, remove the 4 bolts. (*1)
    8. Remove the 2 nuts, 2 bolts, and intake air surge tank. (*2)
    9. Remove the gasket from the intake air surge tank.
      Fig 9: Locating Intake Air Surge Tank Bolts
      G05138180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 2 fuel pipe clamp.
    2. Pinch the tube connector and pull out the fuel pipe.
      NOTE:
      • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector as necessary.
      • It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
      • Only disconnect the quick connector by hand.
      • Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
      • If the pipe and the connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
        Fig 10: Pinching Tube Connector
        G04975007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL INJECTOR ASSEMBLY 
    1. Disconnect the 6 fuel injector connectors.
      Fig 11: Locating Fuel Injector Connectors
      G04975008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and fuel delivery pipe sub-assembly together with the 6 fuel injectors.
      NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe sub-assembly.
      Fig 12: Locating Fuel Delivery Pipe, Fuel Injectors And Bolts
      G04975009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 injector vibration insulators from the intake manifold.
      Fig 13: Locating Injector Vibration Insulators And Intake Manifold
      G05138184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Pull out the fuel injectors from the fuel delivery pipe sub-assembly.
      Fig 14: Pulling Out Fuel Injector From Fuel Delivery Pipe
      G04975011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 6 O-rings from the fuel injectors.
      Fig 15: Identifying Injectors O-Rings
      G04975012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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