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Home >> Toyota >> 2006 >> Prius >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System (1NZ-FXE) >> Fuel Injector >> Removal

Fuel Injector: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    CAUTION:
    • DISCHARGE FUEL SYSTEM PRESSURE procedures must be performed before disconnecting any part of the fuel system.
    • After performing the DISCHARGE FUEL SYSTEM PRESSURE procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray.
    1. Remove the integration relay (unit C: C/OPN relay) from the engine room junction block.
    2. Start the engine. After the engine has stopped, turn the power switch OFF.

      HINT:

      DTC P0171 (system too lean) may be set.

    3. Check that the engine does not start.
    4. Remove the fuel tank cap, and let the air out of the fuel tank.
    5. Disconnect the cable from the 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.
    6. Install the integration relay (unit C: C/OPN relay) to the engine room junction block.
  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK 
    1. Remove the windshield wiper motor and link (see REMOVAL ).
  3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY 
    1. Remove the 2 bolts and disconnect the No. 2 engine room relay block.
    2. Remove the 4 wire harness clamps.
      Fig 1: Removing Front Outer Cowl Top Panel Sub-Assembly
      G04472834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 7 bolts and panel.
  4. REMOVE AIR CLEANER ASSEMBLY (See  REMOVAL  ) 
    Fig 2: Removing Bolts From Panel
    G04472835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Disconnect the brake fluid level switch connector.
    2. Remove the 2 bolts.
    3. Disconnect the claw fitting, then remove the brake master cylinder reservoir.
      Fig 3: Removing Brake Master Cylinder Reservoir Sub-Assembly
      G04472836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE RESERVOIR BRACKET 
    1. Remove the No. 2 fuel vapor feed hose from the hose clamp.
    2. Remove the connector clamp.
    3. Remove the wire harness clamp.
    4. Remove the 3 bolts and reservoir bracket.
      Fig 4: Removing Reservoir Bracket
      G04472837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 2 wire harness clamps.
    2. Disconnect the 4 fuel injector connectors.
    3. Disconnect the 4 ignition coil connectors.
    4. Remove the 3 bolts, then remove the engine wire and brake master cylinder reservoir cover.
      Fig 5: Removing Connectors
      G04472838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and 4 ignition coils.
      Fig 6: Removing Bolts From Ignition Coils
      G04472839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the ventilation hose from the ventilation valve.
    7. Disconnect the No. 2 ventilation hose from the cylinder head cover.
      Fig 7: Disconnecting Ventilation Hose From Ventilation Valve
      G04472840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover.
      Fig 8: Removing Bolts, Seal Washers And Nuts From Cylinder Head Cover
      G04472841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL DELIVERY PIPE 
    1. Disconnect the fuel tube from the fuel delivery pipe.
      1. Remove the No. 1 fuel pipe clamp.
        Fig 9: Removing No. 1 Fuel Pipe Clamp
        G04472842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the fuel tube from the fuel delivery pipe.
        NOTE:
        • Remove dirt or foreign objects on the fuel tube connector before this procedure.
        • Do not allow any scratches or foreign objects on the parts when disconnecting them, as the fuel tube connector has the O-ring that seals the pipe.
          Fig 10: Locating Retainer And O-Ring Of Fuel Tube Connector
          G04472843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Perform this work by hand. Do not use any tools.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tube.
        • If the fuel tube connector and pipe are stuck, push and pull them to release them.
    2. Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors.
      NOTE: Do not drop the fuel injectors when removing the fuel delivery pipe.
      Fig 11: Removing Bolts From Fuel Delivery Pipe
      G04472844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove 2 No. 1 delivery pipe spacers from the cylinder head.
    4. Remove the 4 insulators from the cylinder head.
      Fig 12: Removing Insulators From Cylinder Head
      G04472845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL INJECTOR ASSEMBLY 
    1. Pull out the 4 fuel injectors from the fuel delivery pipe.
      Fig 13: Pulling Out Fuel Injector From Fuel Delivery Pipe
      G04472846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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