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Fuel Injector: Removal

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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:
      • Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
      • After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
    2. Disconnect the 2 fuel pump ECU connectors.
    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 2 fuel pump ECU connectors.
      Fig 1: Locating Fuel Pump ECU Connectors
      G05151892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:
    • Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
    • After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
  3. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY  (See REMOVAL )
  4. REMOVE AIR CLEANER HOSE ASSEMBLY  (See REMOVAL )
  5. DISCONNECT NO. 2 VENTILATION HOSE 
    1. Disconnect the No. 2 ventilation hose from the ventilation valve.
  6. 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 purge VSV from the intake manifold.
  7. REMOVE THROTTLE BODY COVER BRACKET 
    1. Remove the 2 bolts and 2 throttle body cover brackets.
      Fig 2: Locating Bolt And Purge VSV
      G05152133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT FUEL MAIN TUBE 
    1. Remove the fuel pipe clamp.
    2. Disconnect the fuel main tube (see PRECAUTION  ).
      Fig 3: Locating Fuel Main Tube
      G05152134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT FUEL RETURN TUBE 
    1. Disconnect the fuel return tube (see PRECAUTION  ).
      Fig 4: Locating Fuel Return Tube
      G05152135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. 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 RH delivery pipe.
      Fig 5: Identifying Wire Clamps On Engine Wire
      G05152136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Disconnect the fuel return hose from the pressure regulator.
      NOTE: Put a cloth or equivalent under the pressure regulator.
      Fig 6: Locating Fuel Return Hose Of Pressure Regulator
      G05152137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and fuel return pipe from the delivery pipe and intake manifold.

      HINT:

      Move the fuel return pipe aside to secure more work space.

      Fig 7: Identifying Bolts And Fuel Return Pipe
      G05152138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, 2 union bolts, 4 gaskets and front fuel pipe.
    4. Disconnect the 8 injector connectors.
    5. Remove the 4 nuts holding the delivery pipes to the lower intake manifold.
    6. Remove the 2 delivery pipes.
      NOTE: Be careful not to drop the injectors when removing the delivery pipes.
      Fig 8: Locating Nuts Holding Delivery Pipes To Lower Intake Manifold
      G05152139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL INJECTOR ASSEMBLY 
    1. Remove the 8 injectors from the delivery pipe LH and RH.
      NOTE: Do not apply any load to the injector in the horizontal direction.
    2. Remove the O-ring, grommet and insulator from each injector.
      Fig 9: Identifying Injectors On Delivery Pipe
      G05152140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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