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Fuel Injector ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION   ) 
  2. DRAIN ENGINE COOLANT (See  COOLANT  ) 
  3. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (w/ Performance Rod) 
    1. Remove the 2 nuts and upper brace.
  4. REMOVE V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  5. 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-Assembly
    G02588889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE EMISSION CONTROL VALVE SET 
    1. Disconnect the 2 VSV connectors.
      Fig 2: Disconnecting VSV Connectors
      G02588890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the wire harness clamp.
    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 3: Removing Emission Control Valve Set
    G02588891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the throttle motor connector.
      Fig 4: Disconnecting Throttle Motor Connector
      G02588892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the water by-pass hose No. 3.
    3. Disconnect the water by-pass hose No. 2.
    4. Disconnect the union to check valve hose.
    5. Disconnect the ventilation hose.
      Fig 5: Disconnecting Ventilation Hose
      G02588893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 nuts and disconnect the pressure feed tube.
      Fig 6: Disconnecting Pressure Feed Tube
      G02588894Courtesy 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 7: Removing Engine Hanger & Surge Tank Stay No. 1 And 2
      G02588895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using an 8 mm socket hexagon wrench, 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 8: Removing Gasket From Intake Air Surge Tank
    G02588896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT 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 9: Disconnecting Fuel Pipe Sub-Assembly No. 1
    G02588897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL INJECTOR ASSY 
    1. Disconnect the 6 fuel injector connectors.
      Fig 10: Disconnecting Fuel Injector Connectors
      G02588898Courtesy 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 11: Removing Fuel Delivery Pipes With Fuel Injectors
      G02588899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 delivery pipe No. 1 spacers (A) and 6 insulators (B) from the intake manifold.
      Fig 12: Removing Delivery Pipe No. 1 Spacers & Insulators From Intake Manifold
      G02588900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Pull out the fuel injector from the fuel delivery pipe.
    Fig 13: Removing Fuel Injector From Fuel Delivery Pipe
    G02588901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FUEL INJECTOR ASSY 
    1. Install a new grommet to the injector.
    2. Apply a light coat of grease or gasoline to a new O-ring, and install it to the injector.
      Fig 14: Applying Light Coat Of Grease Or Gasoline To O-Ring
      G02588902Courtesy 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.
      Fig 15: Pushing Fuel Injector Twisting Back & Forth
      G02588903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    5. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
      Fig 16: Installing Insulators & Delivery Pipe No. 1 Spacers To Intake Manifold
      G02588904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      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.
  11. 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)

  12. 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 an 8 mm socket hexagon wrench, 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 by-pass hose No. 2.
    11. Connect the water by-pass hose No. 3.
    12. Connect the throttle motor connector.
  13. INSTALL EMISSION CONTROL VALVE SET 

    Torque:  8.0 N.m (82 kgf.cm, 71 in.lbf)

  14. INSTALL AIR CLEANER CAP SUB-ASSY 

    Torque:  5.0 N.m (51 kgf.cm, 44 in.lbf)

  15. CHECK CONNECTION OF VACUUM HOSE (See  REPLACEMENT  ) 
  16. ADD ENGINE COOLANT (See  COOLANT  ) 
  17. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING (3MZ-FE)  ) 
  18. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
  19. INSTALL V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  20. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (w/ Performance Rod) 
    1. Install the upper brace with the 2 nuts.

    Torque:  80 N.m (815 kgf.cm, 59 ft-lbf)

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