Fuel Injector ASSY (2UZ-FE): Replacement

1. Remove the 2 cap nuts and V-bank cover sub-assy.

1. Disconnect the vacuum hoses (for the P/S idle-up and fuel pressure regulator) and ventilation hose.
2. Remove the air cleaner hose assy.

1. Remove the 2 union bolts and 4 gaskets.
2. Remove the bolts and fuel pipe sub-assy.

1. Remove the fuel pipe clamp No. 2.
2. Remove the 3 bolts and disconnect the fuel return pipe sub-assy from the fuel pressure regulator.

   HINT:

   Move it aside to secure more work space.

   Fig 1: Removing Fuel Return Pipe Sub-Assy No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the pulsation damper and 2 gaskets.
2. Disconnect the fuel hose No. 1.
   Fig 2: Disconnecting Fuel Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolts and separate the vacuum switching valve assy from the intake manifold.

1. Disconnect the 8 fuel injector connectors.
2. Remove the 3 bolts and disconnect the engine wire.

1. Remove the 2 nuts, and then the fuel delivery pipe by holding both ends and pulling it straight upward.

1. Remove the 2 nuts, and then the fuel delivery pipe No. 2 by holding both ends and pulling it straight upward.

1. Remove the injector from the delivery pipe.
   NOTE: Do not apply any force to the injector in the horizontal direction because the O-ring might be stuck.
2. Remove the O-ring, grommet and insulator from the injector.

1. Install a new grommet and insulator to the injector.
2. Check that there is no foreign object or damage to the groove of the O-ring of the injector. Apply gasoline to a new O-ring, and install it to the injector.
3. Install the injector to the delivery pipe while turning the injector in both ways.
4. Check that the injector can turn smoothly.
   NOTE: When the injector cannot turn smoothly, the O-ring might be caught in something. In that case, replace the O-ring with a new one.
   Fig 3: Installing Fuel Injector Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the injector with the delivery pipe to the intake manifold.
2. Turn the injector in both ways by approximately 45 degrees.
3. Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts.

   Torque: 21 N.m (214 kgf.cm, 16 ft.lbf) 

1. Install the injector with the delivery pipe to the intake manifold.
2. Turn the injector in both ways by approximately 45 degrees.
3. Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts.

   Torque: 21 N.m (214 kgf.cm, 16 ft.lbf) 

1. Using 2 new gaskets, install the fuel main hose with the fuel pressure pulsation damper.

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

   Fig 4: Installing Fuel Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

1. Install the fuel pipe sub-assy with the bolts.
2. Using 4 new gaskets, install the fuel pipe sub-assy No. 1 with the 2 union bolts.

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)