Fuel Injector ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Camry. However, it is still accessible from the selected car via links, so may be relevant.

DISCHARGE FUEL SYSTEM PRESSURE (See PRECAUTION )
DRAIN ENGINE COOLANT (See REPLACEMENT )
REMOVE FRONT SUSPENSION UPPER BRACE CENTER
1. Remove the 2 nuts and upper brace.
REMOVE V-BANK COVER SUB-ASSY (See REPLACEMENT )
REMOVE AIR CLEANER CAP SUB-ASSY
1. Disconnect the MAF meter connector.
2. Disconnect the 4 vacuum hoses.
3. Disconnect the ventilation hose No. 2.
4. Remove the fuel vapor feed hose from the 2 hose clamps.
5. Loosen the 2 air cleaner cap bolts.
6. Loosen the air cleaner hose clamp bolt, and remove the air cleaner cap.
7. Remove the air cleaner filter element.
  
  Fig 1: Removing Air Cleaner Cap Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EMISSION CONTROL VALVE SET (1MZ-FE ENGINE TYPE)
1. Disconnect the 3 VSV connectors.
2. Remove the wire harness clamp.
  
  Fig 2: Disconnect The 3 VSV connectors & Wire Harness Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the fuel vapor feed hose No. 1.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 3 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts, and then remove the emission control valve set.
  
  Fig 3: Removing The Emission Control Valve Set (1MZ-FE ENGINE TYPE)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EMISSION CONTROL VALVE SET (3MZ-FE ENGINE TYPE)
1. Disconnect the 2 VSV connectors.
2. Remove the wire harness clamp.
  
  Fig 4: Disconnecting The Two VSV Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the fuel vapor feed hose No. 1.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 2 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts and the emission control valve set.
  
  Fig 5: Removing Emission Control Valve Set (3MZ-FE ENGINE TYPE)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE AIR SURGE TANK
1. Disconnect the throttle motor connector.
2. Disconnect the water bypass hose No. 3.
3. Disconnect the water bypass hose No. 2.
4. Disconnect the union to check valve hose.
  
  Fig 6: Removing Hoses From Throttle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the ventilation hose.
  
  Fig 7: Disconnecting Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 3 nuts and separate the pressure feed tube.
  
  Fig 8: Separating Pressure Feed Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 2 bolts and engine hunger No. 1.
8. Remove the 2 bolts and surge tank stay No. 1.
9. Remove the 2 bolts and surge tank stay No. 2.
  
  Fig 9: Removing Bolts Of Engine Hunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a socket hexagon wrench 8, remove the 4 bolts.
11. Remove the 2 nuts, emission control valve bracket and intake air surge tank.
12. Remove the gasket from the intake air surge tank.
  
  Fig 10: Removing Intake Air Surge Tank Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FUEL PIPE SUB-ASSY NO. 1
1. Remove the bolt and disconnect the fuel pipe No. 1.
2. Remove the fuel pressure pulsation damper and 2 gaskets.
3. Remove the fuel pipe No. 2 union bolt and 2 gaskets.
  
  Fig 11: Separating Fuel Pipe Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL INJECTOR ASSY
1. Disconnect the 6 fuel injector connectors.
  
  Fig 12: Identifying Fuel Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts and 2 fuel delivery pipes together with the 6 fuel injectors.
  NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
  
  Fig 13: Removing Fuel Injector Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 4 delivery pipe No. 1 spacers (*1) and 6 insulators (*2) from the intake manifold as shown.
  
  Fig 14: Removing Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Pull out the fuel injector from the fuel delivery pipe.
  
  Fig 15: Pulling Out Fuel Injector From Fuel Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL INJECTOR ASSY
1. Install a new grommet to each injector.
2. Apply a light coat of grease or gasoline to a new O-ring, and install it to each injector.
  
  Fig 16: Installing Grommet To Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply a light coat of grease or gasoline on the place where the fuel delivery pipe contacts the O-ring.
4. Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
  NOTE:
  - Be careful not to twist the O-ring.
  - After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
    
    Fig 17: Turning Fuel Injector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
6. Place the 2 fuel delivery pipes and the 6 fuel injectors together on the intake manifold.
  NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
7. Temporarily install the 4 bolts which are used to attach the fuel delivery pipe to the intake manifold.
  
  Fig 18: Installing Fuel Delivery Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
8. Tighten the 4 bolts.
  Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
9. Connect the 6 fuel injector connectors.
INSTALL FUEL PIPE SUB-ASSY NO. 1
1. Install 2 new gaskets and the fuel pipe No. 2 union bolt.
  Torque: 33 N.m (337 kgf.cm, 24 ft.lbf)
2. Install 2 new gaskets and the fuel pressure pulsation damper.
  Torque: 33 N.m (337 kgf.cm, 24 ft.lbf)
3. Install the fuel pipe No. 1 with the bolt.
  Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
INSTALL INTAKE AIR SURGE TANK
1. Install a new gasket to the intake air surge tank.
2. Install the intake air surge tank and emission control valve bracket with the 2 nuts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
3. Using a socket hexagon wrench 8, tighten the 4 bolts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
4. Install the surge tank stay No. 2 with the 2 bolts.
  Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
5. Install the surge tank stay No. 1 with the 2 bolts.
  Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
6. Install the engine hunger No. 1 with the 2 bolts.
  Torque: 20 N.m (204 kgf.cm, 14 ft.lbf)
7. Install the pressure feed tube with the 3 nuts.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
8. Connect the ventilation hose.
9. Connect the union to check valve hose.
10. Connect the water bypass hose No. 2.
11. Connect the water bypass hose No. 3.
12. Connect the throttle motor connector.
INSTALL EMISSION CONTROL VALVE SET (1MZ-FE ENGINE TYPE)
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL EMISSION CONTROL VALVE SET (3MZ-FE ENGINE TYPE)
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
CHECK CONNECTION OF VACUUM HOSE
ADD ENGINE COOLANT (See REPLACEMENT )
CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )
CHECK FOR FUEL LEAKS (See ON-VEHICLE INSPECTION )
INSTALL V-BANK COVER SUB-ASSY (See REPLACEMENT )
INSTALL FRONT SUSPENSION UPPER BRACE CENTER
1. Install the upper brace with the 2 nuts.
  Torque: 80 N.m (815 kgf.cm, 59 ft.lbf)