Fuel Injector: Service and Repair

Fuel Injector Assy (2UZ-FE):

REPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE V-BANK COVER SUB-ASSY
a. Remove the 2 cap nuts and V-bank cover sub-assy.

3. REMOVE AIR CLEANER HOSE ASSY
a. Disconnect the vacuum hoses (For P/S idle-up and for fuel pressure regulator) and ventilation hose.
b. Remove the air cleaner hose assy.

4. REMOVE FUEL PIPE SUB-ASSY N0.1
a. Remove the 2 union bolts and 4 gaskets.
b. Remove the bolts and fuel pipe sub-assy.




5. SEPARATE FUEL PIPE SUB-ASSY N0.3
a. Remove the 3 bolts and disconnect the fuel return pipe sub-assy from fuel pressure regulator.

HINT: Move it aside for stream lining your work.




6. DISCONNECT FUEL HOSE
a. Remove the pulsation damper and 2 gaskets.
b. Disconnect the fuel hose No. 1.

7. SEPARATE VACUUM SWITCHING VALVE ASSY N0.1
a. Remove the bolts and separate the vacuum switching valve assy from the intake manifold.

8. DISCONNECT ENGINE WIRE
a. Disconnect the 8 fuel injector connectors.
b. Remove the 3 bolts and disconnect the engine wire.

9. REMOVE FUEL DELIVERY PIPE SUB-ASSY
a. Remove the 2 nuts, then the fuel delivery pipe by pulling it straight upward holding the both ends.

10. REMOVE FUEL DELIVERY PIPE SUB-ASSY N0.2
a. Remove the 2 nuts, then the fuel delivery pipe No. 2 by pulling it straight upward holding the both ends.

11. REMOVE FUEL INJECTOR ASSY
a. Remove the injector from the delivery pipe.

NOTE: Do not put any force to the injector in the horizontal direction, because the O-ring might be stuck.

b. Remove the O-ring, grommet and insulator from the injector.




12. INSTALL FUEL INJECTOR ASSY
a. Install a new grommet and an insulator to the injector.
b. Check that there is no foreign object stuck and damage in the groove of the O-ring of the injector. Apply some gasoline to a new O-ring, and install it to the injector.
c. Install the injector to the delivery pipe, rotating the injector both ways.
d. Check that the injector can turn smoothly.

NOTE: When the injector cannot turn smoothly, the O-ring might caught on something. In case of that, the operation should be started after the injector has been removed then the O-ring has been replaced with a new one.

13. INSTALL FUEL DELIVERY PIPE SUB-ASSY N0.2
a. Install the injector with delivery pipe to the intake manifold.
b. Under the above condition, turn the injector both ways by approximately 45 degrees.
c. Inserting a spacer in between the delivery pipe and the intake manifold, install the delivery pipe with injector by 2 nuts.

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

14. INSTALL FUEL DELIVERY PIPE SUB-ASSY
a. Install the injector with delivery pipe to the intake manifold.
b. Under the above condition, turn the injector both ways by approximately 45 degrees.
c. Inserting a spacer in between the delivery pipe and the intake manifold, install the delivery pipe with injector by 2 nuts.

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




15. INSTALL FUEL HOSE
a. Inserting 2 new gaskets in between, install the fuel main hose with the fuel pressure pulsation damper.

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

16. INSTALL VACUUM SWITCHING VALVE ASSY N0.1

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

17. INSTALL FUEL PIPE SUB-ASSY N0.3

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

18. INSTALL FUEL PIPE SUB-ASSY N0.1
a. Install the bolts and fuel pipe sub-assy.
b. Instating 2 new gaskets in between the fuel pipe sub-assy and fuel delivery pipe, install the fuel pipe sub-assy with the union bolt each parts.

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

19. INSTALL AIR CLEANER HOSE ASSY
20. CHECK FUEL LEAK
21. INSTALL V-BANK COVER SUB-ASSY

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