2ZR-FE FUEL  FUEL INJECTOR  REMOVAL  


CAUTION / NOTICE / HINT

HINT:

Perform "Inspection After Repair" after replacing a fuel injector assembly.

Click hereEngine / Hybrid System>2ZR-FE ENGINE CONTROL>SFI SYSTEM>INITIALIZATION


PROCEDURE

Hide 1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


Hide 2. DISCHARGE FUEL SYSTEM PRESSURE

Click hereEngine / Hybrid System>2ZR-FE FUEL>FUEL SYSTEM>PRECAUTION

Hide 3.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Hide 11212 4.REMOVE NO. 2 CYLINDER HEAD COVER

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>REMOVAL

Hide 17705 5.REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Click hereEngine / Hybrid System>2ZR-FE ENGINE CONTROL>THROTTLE BODY>REMOVAL

Hide 17701 6.REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>REMOVAL

Hide 82121 7.DISCONNECT ENGINE WIRE

a.

Disengage the 8 clamps, and then disconnect the 19 connectors.

A325310


b.

Remove the 3 bolts and 3 nuts, and disconnect the engine wire.


Hide 25719 8.REMOVE VACUUM SURGE TANK

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE UNIT>REMOVAL

Hide 23901 9.DISCONNECT FUEL TUBE SUB-ASSEMBLY

NOTICE:

Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


a.
A294335C01
2.865,0.854 2.771,1.188 2.771,1.188 2.667,0.854 false 2.688,1.198 3,1.396 0.313,0.198 10 *a
*a Claw


Disengage the 2 claws to remove the No. 2 fuel pipe clamp.

NOTICE:

Do not reuse the No. 2 fuel pipe clamp.



b.

Disconnect the fuel tube sub-assembly from the fuel delivery pipe sub-assembly.

i.
A062165N01
1.979,0.719 2.49,1.635 2.49,1.635 2.021,1.854 true 2.531,1.552 2.844,1.729 0.313,0.177 10 SST

Install SST (fuel hose puller) to the fuel tube connector as shown in the illustration.

SST
09268-21011  


ii.
A284030C16
2.167,1.344 2.448,1.771 2.448,1.771 2.635,1.771 false 0.708,1.24 1.021,1.396 0.313,0.156 10 false *a 2.74,1.688 3.208,1.948 0.469,0.26 10 false SST
*a Retainer (4 places)


Turn SST (fuel hose puller), align the retainers inside the fuel tube connector with the SST (fuel hose puller) chamfers and insert SST (fuel hose puller) into the fuel tube connector.


iii.

Mount the retainers of the fuel tube connector onto the chamfered part of SST (fuel hose puller).


iv.
A076220C16
2.26,1.573 2.26,1.875 false 0.594,1.375 0.594,1.708 false 1.396,0.875 1.125,0.438 1.125,0.438 1.594,0.875 false 2.917,1.323 2.917,1.531 false 2.156,0.771 2.281,0.438 2.281,0.438 2.417,0.438 false 0.948,0.323 1.25,0.563 0.302,0.24 10 false *b 2.479,0.354 2.833,0.563 0.354,0.208 10 false *a 2.844,1.573 3.073,1.771 0.229,0.198 10 false *e 0.51,1.74 0.719,1.969 0.208,0.229 10 false *c 2.177,1.917 2.385,2.115 0.208,0.198 10 false *d
*a Retainer
*b O-ring
*c Nylon Tube
*d Fuel Tube Connector
*e Fuel Pipe


Slide SST (fuel hose puller) and the fuel tube connector together until they make a "click" sound, and then disconnect the fuel tube connector.

NOTICE:
·

Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

·

Do not forcibly bend, twist or turn the nylon tube.




v.

Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.


vi.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.



Hide 23807 10.REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

a.
A236068

Remove the engine cover joint and wire harness bracket from the intake manifold.


b.
A293911

Remove the bolt to separate the clamp from the cylinder head sub-assembly.


c.
A153007

Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 fuel injector assemblies.

NOTICE:

Do not drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.



Hide 23807V 11.REMOVE NO. 1 DELIVERY PIPE SPACER

a.
A153008

Remove the 2 No. 1 delivery pipe spacers from the cylinder head sub-assembly.


Hide 23250 12.REMOVE FUEL INJECTOR ASSEMBLY

a.
A153009

Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.


b.

Remove the O-ring from each fuel injector assembly.


c.

For reinstallation, attach a tag or label with the corresponding cylinder number to each fuel injector assembly.

NOTICE:

Protect the fuel injector assemblies by covering them with plastic bags.



d.
A153010

Remove the 4 injector vibration insulators from the cylinder head sub-assembly.