Removal and Installation of Fuel Delivery Pipe and Injectors (3S-FE Engine)

If an injector does not operate satisfactorily, before discarding it, try one of the proprietary injector cleaning methods (ultrasonic cleaning). For this, contact one of the authorized Toyota service stations.

Removal · Relieve the fuel system pressure; · Disconnect the negative battery cable; · Remove the air intake chamber; · Remove the bolts and the engine lifting eye together with the intake manifold bracket; · Mark the hoses and disconnect them from the exhaust gas recirculation (EGR) valve located at the rear left of the intake manifold. Remove the nut securing the EGR pipe to the connecting pipe near the distributor, then remove the mounting nuts and remove the EGR valve from the intake manifold. Remove the gasket.

· Remove the bolts and remove the remaining intake manifold bracket from its left side.

· Remove the bolts of the accelerator cable support bracket on the intake manifold and move the bracket with the cable aside.

· Release the high-tension wires from the guides, then disconnect the wires from the spark plugs, noting their positions.

· Disconnect the positive crankcase ventilation hose from the intake manifold. · Release the power steering fluid return hose from the clamp on the engine wire harness cover.

· Disconnect the engine wire harness cover from the camshaft drive mechanism upper cover, releasing the rear mounting first, then the front.

· Remove the lock nuts, then remove the camshaft cover with gasket. Note that the cover is secured by special nuts screwed onto the spark plug tubes together with the seals.

· Disconnect the clips and release the engine wiring harness from the support bracket and the intake manifold.

· Remove the pulsation damper and disconnect the inlet fuel hose from the left end of the fuel delivery pipe, then remove the two washers.

· Release the clamp and disconnect the return fuel hose from the pipe.

· Disconnect the vacuum hose from the fuel pressure regulator.

· Disconnect the injector wiring connectors.

Fig. 4.5.*1. Disconnecting the connectors from the injectors

· Remove the two bolts securing the fuel delivery pipe to the cylinder head.

· Carefully remove the fuel delivery pipe together with the injectors from the cylinder head. Once the injectors are free, rotate the fuel delivery pipe so that the injectors are horizontal and face forward, then remove the assembly through the top of the engine. Remove the insulators and spacers from the cylinder head.

· Disconnect the injectors from the fuel delivery pipe and remove the O-rings. Seals are not reusable; they must be replaced during installation.

Installation · Install in the reverse order of removal, observing the following instructions:

Install new O-rings on all injectors and new seals on the intake manifold or cylinder head (depending on model).

To ease installation of the O-rings on the injectors, and of the injectors into the fuel delivery pipe, lubricate them with a small amount of engine oil.

Install the fuel delivery pipe with the injectors on the intake manifold or cylinder head (depending on model). Install the spacers, then insert the mounting bolts and tighten them to 13 N·m.

If necessary, replace the camshaft cover gasket.

When installing the camshaft cover, apply sealant to the mating surfaces of the camshaft bearing caps and cylinder head, as well as to the semicircular plugs at both ends of the exhaust camshaft. Before installing the cover, make sure the gasket is correctly seated in the cover. Make sure the spark plug tube seals are in place. Tighten the stud nuts to the specified torque (44 N·m).

Install the air intake chamber.

Finally, start the engine and check for fuel leaks.