FUEL INJECTOR (for Port Injection): Removal

PRECAUTION
CAUTION:
- Do not smoke or be near an open flame when working on the fuel system.
- Keep gasoline away from rubber or leather parts.
- Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.
DISCHARGE FUEL SYSTEM PRESSURE
1. Discharge fuel system pressure (see PRECAUTION ).
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.

NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
REMOVE INTAKE MANIFOLD
1. Remove the intake manifold (see REMOVAL ).
DISCONNECT NO. 3 FUEL HOSE
1. Remove the fuel pipe clamp.
2. Pinch the tube connector and then pull out the fuel hose.
  NOTE:
  - Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
  - Do not use any tools to separate the pipe and connector.
  - Do not forcefully bend or twist the nylon tube.
  - Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
  - Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
  - If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
    
    Fig 1: Pinching Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TUBE SUB-ASSEMBLY
1. Lift up the retainer to release its lock.
2. Pinch the tube connector and then pull out the fuel tube.
  NOTE:
  - Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
  - Do not use any tools to separate the pipe and connector.
  - Do not forcefully bend or twist the nylon tube.
  - Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
  - Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
  - If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
    
    Fig 2: Pulling Out Fuel Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
1. Disconnect the 2 connectors.
  
  Fig 3: Identifying Fuel Delivery Pipe Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 4 wire harness clamps.
  
  Fig 4: Identifying Wire Harness Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 4 bolts and 2 fuel delivery pipes.
  NOTE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.
  
  Fig 5: Locating Fuel Delivery Pipes Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 delivery pipe spacers and 8 insulators from the intake manifold.
REMOVE FUEL INJECTOR ASSEMBLY
1. Remove the fuel injector from the fuel delivery pipe.
  NOTE: For reinstallation, attach a tag or label to the injector shaft.
  
  Fig 6: Identifying Injector Shaft Label
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connector from the injector.
  
  Fig 7: Disconnecting Connector From Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring from the fuel injector assembly.
  
  Fig 8: Identifying Fuel Injector O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002