Fuel Injector: Service and Repair

FUEL INJECTORS / REPLACEMENT

Fuel Injector Assy (2ZZ-GE):

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
Refer to Fuel Pressure Release.







2. REMOVE CYLINDER HEAD COVER NO.2
Remove the 3 bolts, nut and cylinder head cover.







3. REMOVE VENTILATION HOSE NO.2
Remove the ventilation hose.







4. REMOVE VENTILATION HOSE
Remove the ventilation hose.







5. DISCONNECT ENGINE WIRE
a. Remove the bolt.
b. Disconnect the 4 fuel injector connectors.
c. Disconnect the cam position sensor connector.







6. REMOVE EFI FUEL PIPE CLAMP
Remove the EFI fuel pipe clamp.







7. REMOVE FUEL DELIVERY PIPE SUB-ASSY
a. 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.







b. Remove the bolt and clamp.







c. Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors and fuel tube.

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







d. Remove the 2 spacers from the cylinder head.







8. REMOVE FUEL INJECTOR ASSY
Pull out the 4 fuel injectors from the fuel delivery pipe.







9. INSTALL FUEL INJECTOR ASSY
a. Install a new insulator to the each fuel injector.
b. Apply a light coat of spindle oil or gasoline to a new O-ring, and install it to the each fuel injector.

NOTE: Never use engine, gear or brake oil.







c. Apply a light coat of spindle oil or gasoline on the place where the fuel delivery pipe touches on O-ring.
d. While turning the fuel injector clockwise and counterclockwise, and push it to the fuel delivery pipe.

NOTE: Be careful not twist the O-ring.
After installing the fuel injectors, check that they turns smoothly. If the fuel injector does not, reinstall it with a new O-ring







10. INSTALL FUEL DELIVERY PIPE SUB-ASSY
a. Install the 2 spacers to the cylinder head.
b. Install the fuel delivery pipe together with the 4 fuel injectors and fuel tube with the 3 bolts.

Torque:
Bolt A ...........29 N.m (296 kgf.cm, 21 ft.lbf)
Bolt B .............9.0 N.m (92 kgf.cm, 80 in.lbf)

NOTE: Be careful not drop the fuel injectors when installing the fuel delivery pipe.
Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.

c. Install the clamp with the bolt.

Torque: ................9.0 N.m (92 kgf.cm, 80 in.lbf)

d. Connect the fuel tube (fuel tube connector) to the fuel pipe.

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

11. CONNECT ENGINE WIRE
a. Connect the composition sensor connector.
b. Connect the 4 fuel injector connectors.
c. Install the bolt.

Torque: .................10 N.m (102 kgf.cm, 7 ft.lbf)

12. INSTALL CYLINDER HEAD COVER NO.2
Install the cylinder head cover with the 3 bolts and nut.

Torque: ........................7.0 N.m (71 kgf.cm, 62 in.lbf)

13. CHECK FUEL LEAK