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Fuel Injector ASSY (3MZ-FE): Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM (3MZ-FE)   ) 
  2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) 
  3. DRAIN ENGINE COOLANT (See  ENGINE COOLANT (3MZ-FE)  ) 
  4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See  REPLACEMENT  ) 
  5. REMOVE V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  6. REMOVE AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  7. REMOVE EMISSION CONTROL VALVE SET 
    1. Disconnect the 2 VSV connectors.
    2. Remove the wire harness clamp.
      Fig 1: Disconnecting Connectors & Removing Wire Harness Clamp
      G02942743Courtesy 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, then remove the emission control valve set.
      Fig 2: Removing Emission Control Valve Set
      G02942744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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 3: Disconnecting Water By-Pass Hose
      G02942745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the ventilation hose.
      Fig 4: Disconnecting Ventilation
      G02942746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 nuts, then remove the pressure feed tube.
      Fig 5: Removing Pressure Feed Tube
      G02942747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 bolts, then remove the engine hunger No. 1.
    8. Remove the 2 bolts, then remove the surge tank stay No. 1.
    9. Remove the 2 bolts, then remove the surge tank stay No. 2.
      Fig 6: Removing Engine Hangers
      G02942748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Disconnect the bond cable No. 1 connector.
    11. Using a socket hexagon wrench 8, remove the 4 bolts.
    12. Remove the 2 nuts, then remove the emission control valve bracket and intake air surge tank.
    13. Remove the gasket from the intake air surge tank.
      Fig 7: Removing Emission Control Valve Bracket
      G02942749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. SEPARATE FUEL PIPE SUB-ASSY NO.1 
    1. Remove the fuel pressure pulsation damper and 2 gaskets.
    2. Remove the fuel pipe No. 2 union bolt and 2 gaskets.
    3. Remove the bolt, then separate the fuel pipe No. 1.
      Fig 8: Separating Fuel Pipe Sub. Assembly No. 1
      G02942750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL INJECTOR ASSY 
    1. Disconnect the 6 fuel injector connectors.
      Fig 9: Removing Fuel Injector Connectors
      G02942751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts, then remove the 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 10: Removing Fuel Injectors
      G02942752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 delivery pipe No. 1 spacers from the intake manifold.
    4. Remove the 6 insulators from the intake manifold.
      Fig 11: Removing Insulators From Intake Manifold
      G02942753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Pull out the fuel injector from the fuel delivery pipe.
      Fig 12: Removing Fuel Injector From Fuel Delivery Pipe
      G02942754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FUEL INJECTOR ASSY 
    1. Install new grommets to each fuel injector.
    2. Apply a light coat of spindle oil or gasoline to new O-rings, then install them to each fuel injector.
      Fig 13: Installing New Grommets & O-Ring To Injector
      G02942755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a light coat of spindle oil or gasoline to 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 injectors, check that they turn smoothly. If not, replace O-ring with a new O-ring.
      Fig 14: Installing Injector In Fuel Delivery Pipe
      G02942756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
      Fig 15: Installing Spacers To Intake Manifold
      G02942757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Place the 2 fuel delivery pipes together with the 6 fuel injectors to 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 attach the fuel delivery pipe to the intake manifold.
    8. Check that the fuel injectors rotate smoothly.

      If the fuel injectors do not rotate smoothly, the probable cause is incorrect installation of the O-ring. Replace it with a new one.

    9. Tighten the 4 bolts.
      1. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 
    10. Connect the 6 fuel injector connectors.
  12. INSTALL FUEL PIPE SUB-ASSY NO.1 
    1. Install 2 new gaskets and fuel pipe No. 2 union bolt.
      1. Torque: 33 N.m (331 kgf.cm, 24 ft.lbf) 
    2. Install 2 new gaskets and fuel pressure pulsation damper.
      1. Torque: 33 N.m (331 kgf.cm, 24 ft.lbf) 
    3. Install the fuel pipe No. 1 with the bolt.
      1. Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 
  13. 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.
      1. Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 
    3. Using a socket hexagon wrench 8, tighten the 4 bolts.
      1. Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 
    4. Install the surge tank stay No. 2 with the 2 bolts.
      1. Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 
    5. Install the surge tank stay No. 1 with the 2 bolts.
      1. Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 
    6. Install the engine hunger No. 1 with the 2 bolts.

      Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

    7. Install the pressure feed tube with the 2 nuts.
      1. 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.
  14. INSTALL EMISSION CONTROL VALVE SET 
    1. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 
  15. INSTALL AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  16. CHECK CONNECTION OF VACUUM HOSE (See  REPLACEMENT  ) 
  17. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) 
    1. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 
  18. ADD ENGINE COOLANT (See  ENGINE COOLANT (3MZ-FE)  ) 
  19. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING FAN SYSTEM (3MZ-FE)  ) 
  20. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
  21. INSTALL V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  22. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See  REPLACEMENT  ) 
  23. SYSTEM INITIALIZATION (See  CHARGING SYSTEM (3MZ-FE)  ) 
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