Removal and Installation of Fuel Delivery Pipe and Injectors (4A-FE Engine)

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

Removal is performed in the following sequence:

· Relieve the fuel system pressure.

· Disconnect the negative battery cable.

· Remove the air intake chamber.

· Remove the bolts and remove the air duct and fuel hose from the inlet air chamber.

· Remove the bolts and the engine lifting eye, then remove the intake manifold support and gasket.

· Disconnect the positive crankcase ventilation hoses and the vacuum sensor hose. Then remove the bolts and nuts and remove the inlet air chamber cover and gasket.

· Release the clamp and disconnect the return fuel hose from the fuel pressure regulator.

· Remove the union bolt and disconnect the inlet fuel hose from the left end of the fuel delivery pipe. Remove the two washers.

· Disconnect the wire connectors from the injectors.

· Remove the mounting bolts and carefully remove the fuel delivery pipe together with the injectors (Fig. 4.5.1). Remove the insulators and spacers from the intake manifold.

Fig. 4.5.1. Removing the Fuel Delivery Pipe

· Disconnect the injectors from the fuel delivery pipe and remove their O-rings (Fig. 4.5.2). Do not reuse the seals; they must be replaced during installation.

Fig. 4.5.2. Disconnecting Injector from Fuel Delivery Pipe

Installation is performed in the reverse order of removal, observing the following notes:

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

· To make it easier to install the O-rings on the injectors and the injectors into the fuel delivery pipe, lubricate them with a small amount of engine oil.

· Install the fuel delivery pipe with injectors on the manifold or cylinder head (depending on model).

· Install the spacers, then insert the mounting bolts and tighten them to the specified torque.

· Finally, start the engine and check for fuel leaks.