Toyota 23209-0F020
Injector Assembly, Fuel

Starting with fuel system pressure discharge and negative battery cable removal it becomes possible to remove 1GR-FE engine fuel injectors. The first step requires draining engine coolant followed by eliminating the V-bank cover. You should start by disconnecting the No. 2 ventilation hose together with separate removal of the air cleaner assembly. The 1GR-FE engine requires separation of the intake air surge tank by disconnecting all components including No. 5 and No. 4 water by-pass hoses, fuel vapor feed hose, ventilation hose and 2 VSV connectors with the throttle motor connector. To remove the surge tank disconnect its three wire harness clamps and hose clamp while removing the three upper bolts securing surge tank stays and throttle body bracket. Deliver the surge tank detachment and its gasket by using a 8 mm socket hexagon wrench to remove 4 bolts with 2 nuts. The fuel pipe sub-assembly No. 1 requires disconnecting by removing fuel pipe clamps while pinching tube connectors and pulling the pipe out in a manner that avoids dirt or foreign matter entering the fuel tube connector. Repetitions of this procedure will occur for the Number 2 fuel pipe subsection. The disconnect process for both fuel pipes should be followed by removing the fuel delivery pipe sub-assembly after disconnecting the 6 fuel injector connectors and taking out the 6 bolts while maintaining injector safety. Draw the 6 injectors completely out from the delivery pipe as the final step.

The procedure to detach the 2UZ-FE engine fuel injector starts with emptying the fuel system pressure. First properly discharge the fuel system pressure before removing both cap nuts and the throttle body cover sub-assembly. The removal process starts by detaching vacuum hoses from P/S idle-up, fuel pressure regulator, and ventilation hose then taking off the air cleaner hose assembly. Start by removing all 2 union bolts along with 4 gaskets from the No. 1 fuel pipe sub-assembly then move to the bolts needed to detach the fuel pipe sub-assembly. Lifting away the fuel return pipe sub-assembly from the fuel pressure regulator will be possible after removing the No. 2 fuel pipe clamp and 3 bolts which serve to disconnect this sub-assembly from the fuel pressure regulator. The fuel hose requires disconnection after the removal of both pulsation damper and 2 gaskets followed by No. 1 fuel hose separation. The separation of the No. 1 vacuum switching valve sub-assembly from the intake manifold becomes possible after removing all bolts. The fuel injector connectors must be disconnected along with the removal of 3 engine wire bolts. Start by unthreading the 2 nuts to remove the fuel delivery pipe sub-assembly before extracting it upward straight. Then continue by removing the No. 2 fuel delivery pipe sub-assembly using the same procedure. Through the final step remove the fuel injector assembly from the delivery pipe while maintaining injector position to avoid damaging the O-ring before taking out its components.

Install the throttle body cover sub-assembly, torqued to 7.5 Nm (80 kgf-cm, 66 ft-lbf).

Secure with 3 upper bolts at 21 Nm (214 kgf-cm, 16 ft-lbf).

Use a socket hexagon wrench 8 to remove the 4 bolts and then take off the 2 nuts, intake air surge tank, and gasket.

Install the intake air surge tank with a new gasket and 2 nuts, tightening to 28 N.m (286 kgf.cm, 21 ft.lbf), then install the 4 bolts with the same torque, followed by the 3 upper bolts at 21 N.m (214 kgf.cm, 16 ft.lbf).

Disconnect the engine wire clamps and remove the fuel return pipe, checking for dirt before disconnecting it by hand.

Start by placing a new grommet on each injector, applying a light coat of gasoline to new O-rings before installing them, and while turning the injectors, push them into the delivery pipes, ensuring the injector connectors face outward. Position the four spacers and eight new insulators on the intake manifold, place the two delivery pipes and injector assemblies on the lower intake manifold, temporarily install the four nuts, and then install the front fuel pipe with the bolt, four new gaskets, and two union bolts.

Connect the No. 2 ventilation hose to the ventilation valve.

Remove the throttle body cover bracket, disconnect engine wires from the No.1 engine hanger and wire bracket, and remove the delivery pipes and injectors, taking care not to drop the injectors.

Connect the PCV hose to the PCV valve, install the accelerator cable clamp and VSV for EVAP to the upper intake manifold, connect the EVAP hose and VSV connector, install the throttle body cover bracket with a bolt, and finally, install the accelerator cable bracket with two nuts torqued to 18 N.m before connecting the accelerator cable to the engine, and reinstalling the fuel pressure pulsation damper, intake air connector, and throttle body cover.

Discharge the fuel system pressure by disconnecting the negative (-) battery terminal cable and waiting at least 90 seconds.

Connect the eight injector connectors.

Disconnect the 8 injector connectors.

Attach the two wire clamps to the brackets on the RH delivery pipe and connect them to the No.1 engine hanger and engine wire bracket, followed by installing the engine wire protector with two bolts.

Temporarily install the 6 bolts to secure the pipe and verify that the injectors rotate smoothly.

Turn them clockwise and counterclockwise while pushing them onto the delivery pipes, ensuring the injector connectors are positioned outward.

Temporarily install the 6 bolts to hold the pipe in place, checking that the injectors rotate smoothly; if not, replace the O-ring of the injector that does not rotate smoothly.

Pull the 6 fuel injectors from the fuel delivery pipe and remove the O-ring and injector vibration insulator from each injector.

Install the intake air surge tank, air cleaner assembly with element, cool air intake hose, and reconnect the negative battery cable, noting that some systems may require initialization.

Place a new insulator on each fuel injector, apply a light coat of spindle oil or gasoline to a new O-ring, and install it on the injector while turning it.