Fuel Injector: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE CYLINDER HEAD COVER NO. 2
4. REMOVE IGNITION COIL NO. 1
5. REMOVE VENTILATION HOSE
a. Disconnect the ventilation hose.
6. REMOVE VENTILATION HOSE NO. 2
a. Disconnect ventilation hose No. 2.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Disconnect the fuel injector connectors.
b. Disconnect the connector and 3 wire harness clamps shown in the illustration and disconnect the engine wire harness.
c. Remove the bolt and remove the wire harness bracket.
d. Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly.
8. DISCONNECT FUEL TUBE SUB-ASSEMBLY
a. Remove the fuel pipe clamp.
b. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector to disconnect the fuel tube out of the fuel delivery pipe sub-assembly.
NOTE:
- Remove any dirt and foreign matter from the fuel tube connector before performing this work.
- Do not allow any scratches or foreign matter 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 parts by covering them with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors.
NOTE: Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.
10. REMOVE DELIVERY PIPE NO. 1 SPACER
a. Remove the 2 delivery pipe No. 1 spacers.
11. REMOVE INJECTOR VIBRATION INSULATOR
a. Remove the 4 injector vibration insulators.
12. REMOVE FUEL INJECTOR ASSEMBLY
a. Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
a. Apply a light coat of gasoline or spindle oil to new Orings, then install one onto each fuel injector.
b. Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the Oring of the fuel injector.
c. While turning the fuel injector left and right, install it onto the fuel delivery pipe.
NOTE:
- Do not twist the O-ring.
- After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.
2. INSTALL INJECTOR VIBRATION INSULATOR
a. Install 4 new injector vibration insulators onto the cylinder head.
3. INSTALL DELIVERY PIPE NO. 1 SPACER
a. Install the 2 No. 1 delivery pipe spacers onto the cylinder head.
NOTE: Install the delivery pipe No. 1 spacer in the correct direction.
4. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Install the fuel delivery pipe sub-assembly with the 4 fuel injectors, then provisionally install the 3 bolts.
NOTE:
- Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
- Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe subassembly.
b. Tighten the 3 bolts to the specified torque.
Torque: 19 Nm (194 kgf.cm, 14 ft. lbs.) for bolt A 9.0 Nm (92 kgf.cm, 80 in. lbs.) for bolt
5. CONNECT FUEL TUBE SUB-ASSEMBLY
a. Insert the fuel tube connector into the fuel delivery pipe until a click sound can be heard.
NOTE:
- Check that there are no scratches or foreign matter around the disconnected parts of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling them.
b. Install the fuel pipe clamp.
6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Apply seal packing to the cylinder head as shown in the illustration.
Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
NOTE:
- Remove any oil from the contact surface.
- Install the cylinder head cover sub-assembly within 3 minutes of applying the seal packing.
- Do not start the engine for at least 2 hours after the installation.
b. Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.
c. Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf.cm, 7.0 ft. lbs.)
d. Install the wire harness bracket with the bolt.
Torque: 13 Nm (133 kgf.cm, 9.6 ft. lbs.)
e. Connect the connector and wire harness clamp shown in the illustration and connect the engine wire harness.
f. Connect the fuel injector connectors.
7. CONNECT VENTILATION HOSE NO. 2.
a. Connect ventilation hose No. 2.
8. CONNECT VENTILATION HOSE
a. Connect the ventilation hose.
9. INSTALL IGNITION COIL NO. 1
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf.cm, 48 in. lbs.)
11. CHECK FOR FUEL LEAKAGE.
12. CHECK FOR ENGINE OIL LEAKAGE
13. INSTALL CYLINDER HEAD COVER NO. 2.