Toyota 23209-0D040
Injector

The first step for servicing fuel injectors requires removal of suspension upper brace and No.2 cylinder head cover and separation of the PCV hose and 3 wire harness clamps from clamp brackets. Unplug the 4 injector connectors and remove 2 bolts which secure the delivery pipe to the cylinder head to complete the disconnection of delivery pipe and 4 injectors without letting the injectors fall. The 4 injectors must be pulled from the delivery pipe after removing all 2 spacers and 4 grommets. Each injector should then have its matching O-ring disassembled for removal. Installation requires applying spindle oil or gasoline to each new O-ring before installing the ring to every injector followed by the procedure of setting both spacers and four new insulators on the cylinder head. Apply little spindle oil or gasoline on each O-ring contact point before feeding the delivery pipe injector while rotating it unto position. Place the 4 injectors into the delivery pipe contacts ensuring each injector faces up. Test the 4 injector movement after installing the delivery pipe to the cylinder head with temporary bolt attachment. If injection movement is restricted, replace the O-ring. Confirm all elements and after confirmation complete the delivery pipe cylinder head bolt installation to 19 N.m (190 kgf.cm, 13 ft.lbf) while attaching the 4 injector connectors. End the installation process by joining the 3 wire harness clamps to the clamp brackets then attaching the PCV hose and installing the No.2 cylinder head cover and suspension upper brace.

Connect the fuel tube (fuel tube connector) to the fuel pipe, install the fuel pipe clamp, and reinstall the No.2 cylinder head cover with the 2 nuts and 2 clips.

Tighten the 2 bolts for the delivery pipe to the cylinder head to a torque of 19 N.m (190 kgf.cm, 14 ft.lbf) for the 1ZZ-FE engine or 29 N.m (290 kgf.cm, 21 ft.lbf) for the 2ZZ-GE engine, and tighten the fuel pipe bolt to 9 N.m (92 kgf.cm, 7 ft.lbf).

Remove the fuel pipe clamp and detach the fuel tube connector from the fuel pipe, ensuring to observe precautions due to retained pressure in the fuel line.

Connect the fuel tube by attaching the fuel tube connector to the fuel pipe, install the fuel pipe clamp, and reinstall the No.2 cylinder head cover with the 2 nuts and 2 clips.

Use Special Service Tool: 09268-21010 to disconnect the fuel tube by assembling the tool to the connection, turning it to align the retainers, and sliding the tool and connector towards the fuel tube assembly.

Apply spindle oil or gasoline to the contact points of the cylinder head and O-rings.

Temporarily install the 2 bolts for the delivery pipe and the bolt for the fuel pipe, and check that the injectors rotate smoothly, replacing any incorrectly installed O-rings if necessary.

Disconnect the 4 injector connectors, remove the 3 bolts, and take out the delivery pipe along with the 4 injectors and fuel pipe.

Carefully remove the two spacers from the cylinder head and pull out the four injectors from the delivery pipe, discarding the O-ring and grommet from each injector.

Remove the 2 delivery pipe spacers and the 4 insulators from the cylinder head, and pull the 4 fuel injectors out of the fuel delivery pipe.

Discharge the fuel system pressure and disconnect the battery negative terminal.

While turning the injector, push it into the fuel delivery pipe, ensuring the O-ring does not twist.

Attach the delivery pipe with the 4 injectors to the cylinder head and temporarily install the 2 bolts to hold the delivery pipe in place.

Do not reuse the retainer, remove it by hand, check for damage or foreign objects, align the connector with the pipe, and push it in until a "click" is heard.

Remove the two bolts securing the delivery pipe to the cylinder head and carefully disconnect the delivery pipe with the four injectors.

Remove the bolt and clamp, then take out the 3 bolts along with the fuel delivery pipe, which includes the 4 fuel injectors and fuel tube, being careful not to drop the injectors.

Install cylinder head cover No. 2 with the 2 nuts and 2 clips, tightening to 7.0 N.m.

While turning the injectors clockwise and counterclockwise, push them into the delivery pipes and install all four injectors, ensuring the injector connectors are positioned upward.

Disconnect the 4 fuel injector connectors, remove the 3 wire harness clamps from the clamp brackets, and take off fuel pipe clamp No. 1 before disconnecting the fuel tube.