Fuel Injector: Service and Repair

Injector:

REMOVAL
1. REMOVE NO. 2 CYLINDER HEAD COVER
2. 1ZZ-FE:

REMOVE PCV HOSE

3. DISCONNECT FUEL TUBE
a. Remove the fuel pipe clamp.
b. Disconnect the fuel tube (fuel tube connector) from the fuel pipe.

CAUTION:
- Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions.
- As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment.

4. REMOVE DELIVERY PIPE AND INJECTORS

NOTE: Be careful not to drop the injectors when removing the delivery pipe.

a. Disconnect the 4 injector connectors from injector.
b. Remove the 3 bolts and delivery pipe together with the 4 injectors and fuel pipe.
c. Remove the 2 spacers from the cylinder head.
d. Pull out the 4 injectors from the delivery pipe.
e. Remove the O-ring and grommet from each injector.

INSTALLATION

1. INSTALL INJECTORS AND DELIVERY PIPES
a. Install the grommet to each injector.
b. Apply a light coat of spindle oil or gasoline to new O-ring and install them to each injector.

c. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches on O-ring.
d. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 4 injectors.
e. Position the injector connector outward.

f. Place the 2 spacers in position on the cylinder head.
g. Apply a light coat of spindle oil or gasoline on the place where a cylinder head touches an O-ring of the injector.
h. Place the delivery pipe and fuel pipe together with the 4 injectors in position on the cylinder head.

i. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head.
j. Temporarily install the bolt holding the fuel pipe to the cylinder head.

k. Check that the injectors rotate smoothly.

HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-ring. Replace the O-ring.

l. Position the injector connector connector outward.

m. Tighten the 2 bolts holding the delivery pipe to the cylinder head.

Torque:
1ZZ-FE: 19 N.m (190 kgf.cm, 14 ft.lbf)
2ZZ-GE: 29 N.m (290 kgf.cm, 21 ft.lbf)

n. Tighten the bolt holding the fuel pipe to the cylinder head.

Torque: 9 N.m (92 kgf.cm, 7 ft.lbf)

2. CONNECT FUEL TUBE
a. Connect the fuel tube (fuel tube connector) to the fuel pipe.

CAUTION: Perform connecting operations of the connector (quick type) after observing the precautions.

b. Install the fuel pipe clamp.

3. INSTALL NO. 2 CYLINDER HEAD COVER

FUEL SYSTEM

a. Observe these precautions when disconnecting the fuel delivery pipe. The structure of the metallic connector is shown as left.
1. Remove the fuel pipe clamp.

2. Get the metallic connector of the fuel tube assembly, pull it out towards the rear and hold it as it is.
3. Assemble SST to the connection as shown.

SST 09268-21010

4. Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector.

5. Hold SST as it at step 4, push the connector towards SST to put the retainers on SST chamfered parts.
6. Slide SST and the connector together towards the fuel tube assembly.

b. Observe these precautions when disconnecting the fuel tube connector (quick type).
1. Remove the fuel pipe clamp.
2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.

3. Be sure to disconnect with hands.
4. When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time.
5. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.

6. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.