Fuel Injector ASSY (2ZZ-GE): Replacement

1. Remove the 3 bolts and nut, then remove the cylinder head cover No. 2.

Fig 1: Removing 3 Bolts And Nut And Cylinder Head Cover No. 2

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1. Remove the ventilation hose No. 2.

Fig 2: Removing Ventilation Hose No. 2

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1. Remove the ventilation hose.

Fig 3: Removing Ventilation Hose

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1. Remove the bolt.
2. Disconnect the 4 fuel injector connectors.
3. Disconnect the cam position sensor connector.
   Fig 4: Disconnecting 4 Fuel Injector Connectors

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4. Remove the fuel pipe clamp No. 1.
5. Disconnect the fuel tube.
   1. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
   Fig 5: Pinching Retainer Of Fuel Tube Connector

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   NOTE:

   • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
   • Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
   • Perform this work by hand. Do not use any tools.
   • Do not forcibly bend, twist or turn the nylon tube.
   • Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
   • If the fuel tube connector and pipe are stuck, push and pull them to release.
   Fig 6: Identifying Fuel Tube Connector And Pipe

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6. Remove the bolt, then remove the clamp.
   Fig 7: Removing Bolt And Clamp

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7. Remove the 3 bolts, then remove the fuel delivery pipe together with the fuel injector.
   NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
   Fig 8: Removing 3 Bolts And Fuel Delivery Pipe Together With Fuel Injector

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8. Remove the 2 delivery pipe spacers from the cylinder head.
9. Remove the 4 insulators from the cylinder head.

Fig 9: Removing 4 Insulators From Cylinder Head

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1. Pull the 4 fuel injectors out of the fuel delivery pipe.

Fig 10: Pulling 4 Fuel Injectors Out Of Fuel Delivery Pipe

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1. Apply a light coat of gasoline or spindle oil to a new CD-ring, then install it onto each fuel injector.
   Fig 11: Applying A Light Coat Of Gasoline Or Spindle Oil To A New Cd-Ring

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2. Apply a light coat of gasoline or spindle oil to the fuel delivery pipe which comes into contact with the O-ring of the fuel injector.
3. Apply a light coat of gasoline or spindle oil to the O-ring again, then install the fuel injector right and left into the fuel delivery pipe.
   NOTE: Make sure that the O-ring is not cracked or jammed when installing.
   Fig 12: Applying A Light Coat Of Gasoline Or Spindle Oil To Fuel Delivery Pipe

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4. Check that the fuel injector rotates smoothly.

If the fuel injector does not rotate, replace the O-ring.

1. Install 4 new insulators into the cylinder head.
2. Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
   NOTE: Make sure that the delivery pipe No. 1 spacer is in the correct direction when installing.
   Fig 13: Installing 4 New Insulators Into Cylinder Head

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3. Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the fuel delivery pipe sub-assy with the 3 bolts.
   NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe.
4. Check that the fuel injector rotates smoothly.

   If the fuel injector does not rotate, replace the O-ring.

5. Retighten the 3 bolts to the specified torque.
   Fig 14: Tightening Fuel Delivery Pipe Sub-Assy With 3 Bolts

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   Torque: 

   29 N.m (296 kgf.cm, 21 ft.lbf) for bolt A 

   9.0 N.m (90 kgf.cm, 80 in..lbf) for bolt B 

6. Install the clamp with the bolt.

   Torque: 9.0 N.m (90 kgf.cm, 80 in..lbf) 

   Fig 15: Installing Clamp With Bolt

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7. Connect the fuel tube.
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tube to the pipe.
   NOTE:

   • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
     Fig 16: Aligning Fuel Tube Connector With Pipe And Pushing Fuel Tube Connector

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   • After connecting the fuel tube, check that the fuel tube is securely connected by pulling the fuel tube connector.
8. Install the fuel pipe clamp No. 1.
9. Connect the camshaft position sensor connector.
10. Connect the 4 fuel injector connectors.
11. Tighten the bolt.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) 

Fig 17: Connecting 4 Fuel Injector Connectors

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1. Install the ventilation hose.

Fig 18: Installing Ventilation Hose

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1. Install the ventilation hose No. 2.

Fig 19: Installing Ventilation Hose No. 2

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Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

1. Install the cylinder head cover No. 2 with the nut and 3 bolts.

Torque: 7.0 N.m (70 kgf.cm, 62 in..lbf) 

Fig 20: Installing Cylinder Head Cover No. 2 With Nut And 3 Bolts

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