Toyota 23209-09151
Injector

The fuel injector replacement requires discharging the fuel pressure from the system before starting work. The next procedure requires the removal of the power cable from the negative battery terminal. Following removal of the V-bank cover sub-assembly the air cleaner hose assembly needs to be detached. The next steps require the removal of the No. 1 engine cover sub-assembly along with the removal of the No. 3 engine cover. Proceed with separating the No. 2 fuel tube from the fuel pressure regulator before removing the No. 1 fuel tube from the fuel delivery pipe on both RH and LH sides. End the fuel hose connection to the fuel delivery pipe located on the LH side. Unplug the ventilation hose and No. 6 wire harness connector from the fuel delivery pipe sub-assembly RH before uninstalling both secure bolts and pulling the pipe upward straight while maintaining both endpoints. Detach the device which keeps the delivery pipes apart and the four insulators from the cylinder head RH side. Follow the same steps to detach the fuel delivery pipe sub-assembly LH starting with connector No. 7 removal then unbolting 2 fasteners before continuing with the extraction procedure. To complete the removal process remove the fuel injector assembly by detaching the fuel delivery pipe and unconnecting the injector connector and affix a label to the injector shaft for easy reassembly. Proceed by extracting both the fuel injector O-ring along with detaching three clamps which will allow removal of the delivery pipe No. 6 wire harness on the right-hand side followed by another round of clamp detachment to eliminate the delivery pipe No. 7 wire harness on the left-hand side.

Start the fuel injector assembly installation for the 2UZ-FE engine by treating each new O-ring with a small drop of gasoline then placing one on each injector before inserting the 8 injectors onto the delivery pipes by turning them clockwise and counterclockwise while orienting the injector connectors outward. Fit the intake manifold with 8 new insulators before setting the 2 delivery pipes and injector assemblies onto the lower intake manifold while temporarily securing its 4 nuts. Use the specified components to assemble the No. 1 fuel pipe sub-assembly by installing the bolt along with 4 new gaskets, 2 union bolts, torquing the union bolts to 39 Nm (398 kgf-cm, 29 ft-lbf) and the bolt to 7.5 Nm (76 kgf-cm, 66 in-lbf). The installation of the fuel return pipe with 3 bolts reaches a torques of 7.5 Nm (76 kgf-cm, 66 in-lbf) while the fuel return hose connects to the fuel pressure regulator. Inspection of the injectors should verify their smooth rotation but if any injector fails to rotate properly the O-ring of that defective injector needs replacement. Secure the lower intake manifold delivery pipes with 4 nuts fastened to 21 Nm torque while attaching the 8 injector connectors. The engine wire gets its clamps installed onto the brackets found on the right-hand delivery pipe. Next the clamps are connected to both the No. 1 engine hanger and engine wire bracket before attaching the engine wire protector through two bolts. Connect the No. 2 fuel pipe sub-assembly with a secure connection until the "click" sound is detected then confirm that no damage or foreign objects exist in the connectors prior to and after completion. The installation sequence should be repeated on the No. 1 fuel pipe sub-assembly. Attaching the EFI fuel pipe clamp requires installation of 2 throttle body cover brackets with 2 bolts that need torquing to 7.5 Nm (76 kgf-cm, 66 in-lbf). Secure the No. 2 ventilation hose to the ventilation valve followed by a connection of the hose assembly to the air cleaner and the throttle body cover sub-parts. Finally, inspect for fuel leaks.

Install the No. 1 engine cover sub-assembly, the No. 3 engine cover, and the air cleaner hose assembly.

Disconnect the No. 7 wire harness connector, remove the 2 bolts, and follow the same removal procedure as for the RH side.

Install the EFI fuel pipe clamp, then install the 2 throttle body cover brackets with 2 bolts, torquing them to 7.5 Nm.

Check for engine coolant leaks.

Disconnect the engine wire clamps from the No. 1 engine hanger and engine wire bracket, as well as the 2 wire clamps on the engine wire from the brackets on the delivery pipe.

Disconnect the 2 fuel pump ECU connectors and crank the engine again to confirm it does not start.

Inspect the fuel system for leaks and check for engine coolant leaks.