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-ASSEMBLY
a. Remove the 2 cap nuts and V-bank cover sub-assembly.

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

4. REMOVE FUEL PIPE SUB-ASSEMBLY NO.1
a. Remove the 2 union bolts and 4 gaskets.
b. Remove the bolts and fuel pipe sub-assembly.

5. SEPARATE FUEL PIPE SUB-ASSEMBLY NO.3




a. Remove the fuel pipe clamp No.2.
b. Remove the 3 bolts and disconnect the fuel return pipe sub-assembly from the fuel pressure regulator.

HINT: Move it aside to secure more work space.

6. DISCONNECT FUEL HOSE




a. Remove the pulsation damper and 2 gaskets.
b. Disconnect the fuel hose No.1.

7. SEPARATE VACUUM SWITCHING VALVE ASSEMBLY NO.1
a. Remove the bolts and separate the vacuum switching valve assembly 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-ASSEMBLY
a. Remove the 2 nuts, and then the fuel delivery pipe by holding both ends and pulling it straight upward.

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

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

NOTE: Do not apply 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 ASSEMBLY




a. Install a new grommet and insulator to the injector.
b. Check that there is no foreign object or damage to the groove of the O-ring of the injector. Apply gasoline to a new O-ring, and install it to the injector.
c. Install the injector to the delivery pipe while turning the injector in both ways.
d. Check that the injector can turn smoothly.

NOTE: When the injector cannot turn smoothly, the O-ring might be caught in something. In that case, replace the O-ring with a new one.

13. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY NO.2
a. Install the injector with the delivery pipe to the intake manifold.
b. Turn the injector in both ways by approximately 45 degrees.
c. Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts.
Torque: 21 N.m (214 kgf.cm, 16 ft.lbf)

14. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
a. Install the injector with the delivery pipe to the intake manifold.
b. Turn the injector in both ways by approximately 45 degrees.
c. Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts.
Torque: 21 N.m (214 kgf.cm, 16 ft.lbf)

15. INSTALL FUEL HOSE




a. Using 2 new gaskets, 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 ASSEMBLY NO.1
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

17. INSTALL FUEL PIPE SUB-ASSEMBLY NO.3
Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)

18. INSTALL FUEL PIPE SUB-ASSEMBLY NO.1
a. Install the fuel pipe sub-assembly with the bolts.
b. Using 4 new gaskets, install the fuel pipe sub-assembly No.1 with the 2 union bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

19. INSTALL AIR CLEANER HOSE ASSEMBLY
20. CHECK FUEL LEAK
21. INSTALL V-BANK COVER SUB-ASSEMBLY
Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)