Fuel Injector ASSY (2GR-FE): Replacement

1. Disengage the 3 clips and remove the v-bank cover.
   NOTE: Be sure to disengage the clips in the order from A to B.
   Fig 1: Removing V-Bank Cover Sub-Assy

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1. Disconnect the 3 vacuum hoses.
2. Disconnect the ventilation hose No.1.
3. Disconnect the air flow meter connector.
4. Separate the fuel vapor feed hose No.1.
5. Loosen the hose clamp bolt.
6. Remove the 3 clamps and air cleaner cap with air cleaner hose.
   Fig 2: Removing Air Cleaner Cap With Air Cleaner Hose

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1. Disconnect the 2 water by-pass hoses from the throttle w/motor body assy.
2. Disconnect the vapor feed hose.
3. Disconnect the throttle w/motor body assy connector and clamp.
   Fig 3: Disconnecting Water By-Pass Hoses From Throttle W/Motor Body Assy

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4. Disconnect the ventilation hose No.2.
5. Disconnect the union to check valve hose.
   Fig 4: Disconnecting Ventilation Hose No.2 & Union To Check Valve Hose

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6. Remove the bolt and vacuum hose clamp.
   Fig 5: Removing Bolt & Vacuum Hose Clamp

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7. Disconnect the connector.
   Fig 6: Disconnecting Connector

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8. Using a 5 mm socket hexagon wrench, remove the 4 bolts.
9. Remove the 2 nuts, 2 bolts and intake air surge tank.
10. Remove the gasket from the intake air surge tank.
    Fig 7: Removing Gasket From Intake Air Surge Tank

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1. Remove the fuel pipe clamp No.2.
2. Pinch the tube connector and then pull out the fuel pipe.
   NOTE:

   • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
   • Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.
     Fig 8: Removing Fuel Pipe Clamp No.2

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   • Do not use any tools in this operation.
   • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
   • When the pipe and the connector are stuck, push and pull the connector to release and pull the connector out carefully.
     Fig 9: Sectional View Of Fuel Tube Sub-Assy

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1. Disconnect the 6 fuel injector connectors.
   Fig 10: Disconnecting Fuel Injector Connectors

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2. Remove the 5 bolts and fuel delivery pipe together with the 6 fuel injectors.
   NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
   Fig 11: Removing Fuel Delivery Pipe Together With Fuel Injectors

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3. Remove the 6 insulators from the intake manifold.
   Fig 12: Removing Insulators From Intake Manifold

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4. Pull out the fuel injector from the fuel delivery pipe.
   Fig 13: Removing Fuel Injector From Fuel Delivery Pipe

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1. Apply a light coat of spindle oil or gasoline to new O-rings, and install it to each injector.
   Fig 14: Installing O-Ring

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2. Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts the O-ring.
3. Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
4. Position the fuel injector connector outward.
   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 15: Installing Injector

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5. Install 6 new insulators to the intake manifold.
   Fig 16: Installing Insulators To Intake Manifold

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6. Place the fuel delivery pipe and the 6 fuel injectors together to the intake manifold.
   NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
7. Temporarily install the 6 bolts which are used to hold the fuel delivery pipe to the intake manifold.
   NOTE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
8. Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

   Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 

   Fig 17: Placing Fuel Delivery Pipe & Fuel Injectors Together To Intake Manifold

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9. Connect the 6 fuel injector connectors.
   Fig 18: Connecting Fuel Injector Connectors

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1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
   NOTE:

   • Check that there is no damage or foreign objects on the connected part of the fuel pipe.
   • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
2. Install the fuel pipe clamp No.2.
   Fig 19: Installing Fuel Pipe Clamp No.2

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1. Install a new gasket to the intake air surge tank.
2. Using a 5 mm hexagon socket wrench, install the 4 bolts.

   Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

3. Install the intake air surge tank with the 2 nuts and 2 bolts.

   Torque: 

   Nut: 16 N.m (163 kgf.cm, 12 ft.lbf) 

   Bolt: 21 N.m (214 kgf.cm, 15 ft.lbf) 

   Fig 20: Installing Intake Air Surge Tank

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4. Connect the connector.
   Fig 21: Connecting Connector

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5. Install the vacuum hose clamp with the bolt.

   Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

   Fig 22: Installing Vacuum Hose Clamp With Bolt

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6. Connect the union to check valve hose.
7. Connect the ventilation hose No.2.
   Fig 23: Connecting Ventilation Hose No.2

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8. Install the clamp and connect the throttle w/motor body assy connector.
9. Connect the vapor feed hose.
10. Connect the 2 water by-pass hoses to the throttle w/motor body assy.
    Fig 24: Connecting Water By-Pass Hoses To Throttle W/Motor Body Assy

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1. Install the 3 clamps and air cleaner cap with air cleaner hose.
2. Tighten the hose clamp bolt.

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

3. Connect the air flow meter connector.
4. Connect the ventilation hose No.1.
5. Connect the 3 vacuum hoses.
6. Connect the fuel vapor feed hose No.1.
   Fig 25: Installing Air Cleaner Cap With Air Cleaner Hose

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1. Engage the 3 clips and install the v-bank cover.
   NOTE: Be sure to engage the clips in the order from A to B.
   Fig 26: Installing V-Bank Cover Sub-Assy

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Some systems need initialization when disconnecting the battery terminal.