Removal [12/2023 - ]: Procedure

Refer to REMOVAL [12/2023 - ] 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 2 fuel pipe sub-assembly.
   2. Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: If fuel intrudes into the combustion chamber, there may be adverse effects to the engine main body. Do not remove the fuel pressure sensor from the fuel delivery pipe with sensor assembly LH. If the fuel pressure sensor is removed, replace the fuel pressure sensor (fuel delivery pipe with sensor assembly LH) with a new one. Make sure not to touch or strike the tips of the direct fuel injector assemblies. Pull and remove the fuel delivery pipe with sensor assembly LH in a straight line without tilting it.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Disconnect the fuel pressure sensor connector.
   2. Remove the bolt.
   3. Disengage the clamp to disconnect the No. 7 engine wire from the fuel delivery pipe with sensor assembly LH.
   4. Remove the 2 bolts, 2 nuts and fuel delivery pipe with sensor assembly LH with the direct fuel injector assemblies.
   5. Disconnect the 3 direct fuel injector assembly connectors and remove the No. 7 engine wire.

NOTE: If fuel intrudes into the combustion chamber, there may be adverse effects to the engine main body. Make sure not to touch or strike the tips of the direct fuel injector assemblies. Pull and remove the fuel delivery pipe RH in a straight line without tilting it.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the bolt.
   2. Disengage the clamp to disconnect the No. 6 engine wire from the fuel delivery pipe RH.
   3. Remove the 2 bolts, 2 nuts and fuel delivery pipe RH with the direct fuel injector assemblies.
   4. Disconnect the 3 direct fuel injector assembly connectors and remove the No. 6 engine wire.

NOTE: Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH O-ring. After removing the direct fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH side. Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Secure the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH in a vise between aluminum plates and pull out the 6 fuel injector assemblies.
      NOTE:

      Do not overtighten the vise.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not damage the area that contacts the O-ring.

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   1. Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   O-ring

   *2

   No. 1 Fuel Injector Back-up Ring

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.
      NOTE:

      • Excessively pinching the fuel injector seal may damage the groove of the direct fuel injector assembly.
      • If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.
   2. Remove the fuel injector seal from each direct fuel injector assembly.