Fuel Injector ASSY (1MZ-FE/3MZ-FE): Replacement

1. Remove the 2 nuts and upper brace.

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

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1. Disconnect the 3 VSV connectors.
2. Remove the wire harness clamp.
   Fig 2: Identifying VSV Connectors And Wire Harness Clamp

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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: Disconnecting Fuel Vapor Feed Hoses

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1. Disconnect the 2 VSV connectors.
2. Remove the wire harness clamp.
   Fig 4: Identifying VSV Connectors And Wire Harness Clamp

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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: Disconnecting Fuel Vapor Feed Hoses

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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 Intake Air Surge Tank

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5. Disconnect the ventilation hose.
   Fig 7: Disconnecting Ventilation Hose

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6. Remove the 3 nuts and separate the pressure feed tube.
   Fig 8: Identifying Pressure Feed Tube And Nuts

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7. Remove the 2 bolts and engine hanger 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: Identifying Surge Tank Stays And Bolts

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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: Identifying Bolts And Nuts

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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 No. 1

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1. Disconnect the 6 fuel injector connectors.
   Fig 12: Removing Fuel Injector Connectors

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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: Identifying Bolts, Fuel Delivery Pipes And Fuel Injectors

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3. Remove the 4 delivery pipe No. 1 spacers (*1) and 6 insulators (*2) from the intake manifold.
   Fig 14: Identifying Delivery Pipe Spacers (*1) And Insulators (*2)

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4. Pull out the fuel injector from the fuel delivery pipe.
   Fig 15: Pulling Out Fuel Injector From Fuel Delivery Pipe

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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: Identifying Fuel Injector O-Ring And Grommet

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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: Installing Fuel Injector

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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: Placing Fuel Delivery Pipes And Fuel Injectors On Intake Manifold

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   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.

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) 

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.

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

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

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

1. Install the upper brace with the 2 nuts.

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