Toyota 23209-09175
Injector

A fuel injector removal requires beginning by releasing the fuel system pressure. After removing the negative battery cable it is essential to note that certain systems need initialization following the reinstallation of the cable. Start by removing both the No. 1 engine cover sub-assembly together with the air cleaner cap sub-assembly. The mechanic must follow this procedure: remove the No. 1 fuel pipe clamp along with pinching the tube connector to free the pipe from the connector while verifying clean tubing before continuing with hose handling without tools and without hose bending. Secure the connector inside a plastic bag protection while removing the sub-assembly of the fuel tube from its fuel hose clamp. The wire harness disconnect process requires separating 4 fuel injector connectors as well as 3 additional connectors and 2 bolts and wire harness brackets and 2 clamps. The fuel delivery pipe sub-assembly can be removed by slowly extracting the fuel delivery pipe with its 4 fuel injectors using the 2 bolts that need to be unscrewed first while keeping the injectors protected from falling. The cylinder head requires the removal of 2 fuel delivery spacers as well as the 4 injector vibration insulators before extracting the 4 fuel injectors from the fuel delivery pipe.

The first step for installing new O-rings on fuel injectors requires a thin petroleum layer to lubricate them before putting each ring into position. Work with a thin layer of gasoline or spindle oil both on the fuel delivery pipe area that touches the fuel injector O-ring and on the O-ring itself before installing the fuel injectors onto the pipe while confirming the O-ring remains intact and undamaged. A broken fuel injector will become stiff to rotate so you must replace the O-ring. When installing the fuel delivery pipe sub-assembly begin with mounting 4 new injector vibration insulators to the cylinder head followed by the 2 fuel delivery spacers which have a longer protrusion on the cylinder head side. Secure the fuel delivery pipe with its 4 fuel injectors onto the cylinder head while maintaining the installation of 2 temporary bolts to achieve this step before checking for dropped injectors. Verify that the fuel injector moves easily before tightening the 2 bolts by applying torque to 21 Nm (214 kgf-cm, 15 ft-lbf). The 2 wire harness brackets should be installed using 2 bolts that reach 10 Nm torque (102 kgf-cm, 7 ft-lbf) whereas the 3 connectors and 4 fuel injector connectors should be connected after which the 2 clamps should be installed to join the wire harness. Squeeze the tube connector onto the pipe framework to secure attachment while also verifying there are no foreign objects or damages on either connecting piece. Test the connection by trying to disassemble the components. Fasten the fuel tube sub-assembly along with the No. 1 fuel pipe clamp onto the fuel hose clamp. Follow the installation procedure for the air cleaner cap sub-assembly and the No. 1 vacuum switching valve assembly and the No. 1 engine cover sub-assembly and the outer cowl top panel. After mounting the windshield wiper motor and link assembly, connect the cable to the negative battery terminal while checking if initializations are necessary upon completion of reconnection. Finally, inspect for fuel leaks.

Install 4 new insulators into the cylinder head and place the 2 delivery pipe spacers onto the cylinder head.

Install the air cleaner cap sub-assembly and the No. 1 engine cover sub-assembly.

Apply a light coat of gasoline or spindle oil to new O-rings and install one onto each fuel injector.

Disconnect the wire harness by removing the 4 fuel injector connectors, 3 additional connectors, 2 bolts, and 2 wire harness brackets, and detach the 2 clamps.