FUEL INJECTOR (for Direct Injection): Removal

DISCHARGE FUEL SYSTEM PRESSURE
1. Discharge fuel system pressure (see PRECAUTION ).
REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
1. Remove the fuel pressure pulsation damper (see REMOVAL ).
REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY
1. Disconnect the fuel pump connector.
2. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the fuel pipe from the fuel pump.
  NOTE: Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump.
  
  Fig 1: Fixing Union Bolt On Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts on the delivery pipe side and remove the fuel pipe.
4. Remove the O-ring, backup rings and E-ring from the fuel pipe
REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY
HINT:

The removal procedures are the same as for the No. 3 fuel pipe sub-assembly
REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

Fig 3: Identifying No. 1 Engine Cover Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

Fig 4: Identifying No. 2 Engine Cover Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH

Fig 5: Identifying No. 2 Engine Cover Sub-Assembly Lh
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY
1. Using a 19 mm union nut wrench, remove the fuel pipe
  
  Fig 6: Removing No. 4 Fuel Pipe Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL DELIVERY PIPE
1. Disconnect the fuel relief valve connector and No. 3 fuel hose.
  
  Fig 7: Locating No. 3 Fuel Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 4 injector connectors.
  
  Fig 8: Locating Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 5 bolts and delivery pipe from the cylinder head
  NOTE:
  - Be extremely careful not to touch or strike the tips of the injectors.
  - Pull and remove the fuel delivery pipe in a straight line without tilting it.
4. Remove the 4 injector vibration insulators from the cylinder head.
REMOVE NO. 2 FUEL DELIVERY PIPE
1. Disconnect the fuel pressure sensor connector
  
  Fig 10: Identifying Fuel Pressure Sensor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 4 injector connectors.
  
  Fig 11: Locating Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 5 bolts and delivery pipe from the cylinder head
  NOTE:
  - Be extremely careful not to touch or strike the tips of the injectors.
  - Pull and remove the fuel delivery pipe in a straight line without tilting it.
4. Remove the 4 injector vibration insulators from the cylinder head.
REMOVE FUEL INJECTOR ASSEMBLY
1. Secure the delivery pipe between aluminum plates in a vise and pull out the injector in a straight line.
  NOTE:
  - Do not overtighten the vise.
  - Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
  - For reinstallation, attach a tag or label to the injector shaft.
2. Remove the nozzle holder clamp from the injector
3. Remove the O-ring, backup rings and E-ring from the fuel injector
REMOVE FUEL INJECTOR SEAL
1. Using the tips of needle-nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it Repeat this for the other injector seal
  NOTE:
  - Excessively pinching the injector seal may damage the groove of the injector.
  - If an injector is dropped or the tip of the injector is struck, replace it with a new one.
    
    Fig 14: Removing Fuel Injector Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 injector seals from the injector.