1GR-FE FUEL – FUEL INJECTOR FU–11

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(See page FU-1)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. DRAIN ENGINE COOLANT (See page CO-3)
4. REMOVE V-BANK COVER (See page ES-414)
5. REMOVE AIR CLEANER ASSEMBLY (See page ES-
415)
6. REMOVE INTAKE AIR SURGE TANK
(a) Disconnect the water by-pass hose No. 5.

A075597E01
FU
(b) Disconnect the water by-pass hose No. 4.

A075598E01

(c) Disconnect the fuel vapor feed hose.

A075644E01
 FU–12 1GR-FE FUEL – FUEL INJECTOR

(d) Disconnect the ventilation hose.

A075645E01

(e) Disconnect the 2 VSV connectors.

(f) Disconnect the throttle motor connector.
(g) Remove the 3 wire harness clamps and hose
clamp.

FU

A075646E01

(h) Remove the 3 upper bolts which are used to secure

the 2 surge tank stays and throttle body bracket.

A075647E01

(i) Using an 8 mm socket hexagon wrench, remove the

4 bolts.
(j) Remove the 2 nuts, then remove the intake air
surge tank and gasket.

A075648E02
 1GR-FE FUEL – FUEL INJECTOR FU–13

7. DISCONNECT NO.1 FUEL PIPE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp.
(b) Pinch the tube connector, and then pull the fuel pipe
out of the pipe as shown in the illustration.
2 Pull
NOTICE:
1 Pinch 1 Pinch • Remove any dirt and foreign objects from 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
Tube Connector
Nylon Tube 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
O-ring Pipe tube.
• If the fuel tube connector and pipe are stuck,
A121823E01 push and pull to release them. FU
8. DISCONNECT NO.2 FUEL PIPE SUB-ASSEMBLY
(a) Remove the fuel pipe clamp.
(b) Pinch the tube connector, and then pull the fuel pipe
2 Pull out of the pipe as shown in the illustration.
NOTICE:
• Remove any dirt and foreign objects from the
fuel tube connector before performing this
work.
• Do not allow any scratches or foreign objects
1 Pinch
on the parts when disconnecting, as the fuel
tube connector has the O-ring that seals the
pipe.
Tube Connector • Perform this work by hand. Do not use any
Nylon Tube 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
O-ring Pipe tube.
• If the fuel tube connector and pipe are stuck,
A121824E01 push and pull to release them.
 FU–14 1GR-FE FUEL – FUEL INJECTOR

9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Disconnect the 6 fuel injector connectors.
(b) Remove the 6 bolts and fuel delivery pipe together
with the 6 fuel injectors.
NOTICE:
Be careful not to drop the injectors when
removing the fuel delivery pipe.

A075652E01

10. REMOVE FUEL INJECTOR

(a) Pull the 6 injectors out of the delivery pipe.

FU Delivery Pipe

Injector

A075653E05

INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
Ohmmeter
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard
Tester Connection Specified Condition
1 -2 11.6 to 12.4 Ωat 20°C (68°F)
A095332E03
If the result is not as specified, replace the fuel
injector.
(b) Check the injection volume.
Pressure Fuel Tube
Regulator
NOTICE:
Connector
• Perform the test in a well-ventilated area and
SST watch out for flames.
• Handle the fuel tube connector carefully.
SST (1) Prepare a new fuel tube.
SST HINT:
Part No. 23801-0P010
Injector
A075912E01
 1GR-FE FUEL – FUEL INJECTOR FU–15

(2) Using a cutter knife, cut the fuel tube protector.

Fuel Tube Connector Tear the protector by hand, then remove the
fuel tube connector.
NOTICE:
If the protector is cut too deeply with the
cutter, the O-ring of the fuel tube connector
will be damaged.

A062159E01

(3) Install the fuel tube connector into SST (hose),

then connect the tube connector to the fuel
pipe.
SST 09268-41047 (95336-08070)
SST (Hose)
CAUTION:
Connect the fuel tube connector (quick
type) after observing the precautions.
Fuel Tube Connector
(4) Remove the pressure regulator(see page 11-
40).
B012947E04 (5) Install the O-ring onto the fuel inlet of the FU
pressure regulator.
(6) Connect SST (hose) to the fuel inlet of the
Pressure
Regulator
pressure regulator with another SST (union)
and the 2 bolts.
SST
SST 09268-41047 (95336-08070, 09268-
(Hose)
41091)
SST Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(Union) (7) Connect the fuel return hose to the fuel outlet of
the pressure regulator.
Fuel Return Hose
A076630E01

(8) Install a new O-ring onto the injector.

O-Ring (9) Connect SST (adaptor and hose) to the injector
SST
and hold the injector and union with SST
(clamp).
SST 09268-41047 (95336-08070), 09268-
SST SST 41140, 09268-41400
(Adapter) (Clamp) (10) Set the injector in a graduated cylinder.
CAUTION:
Vinyl Tube Install a suitable vinyl tube onto the injector
A075914E03 to prevent gasoline splashes.

(11) Connect the intelligent tester to the DLC3.

Intelligent
(12) Turn the ignition switch to ON.
Tester
(13) Turn the intelligent tester ON.
(14) Select the following menu items: DIAGNOSIS /
ENHANCED OBD ll / ACTIVE TEST / FUEL
PUMP / SPD / ON.
(15) Install SST onto the fuel injector.
DLC3 CAN VIM SST 09842-30080

G035612E02
 FU–16 1GR-FE FUEL – FUEL INJECTOR

(16) Connect SST to the battery, then measure the

injection volume for 15 seconds. Perform the
inspection 2 or 3 times, then calculate the
average.
Standard:
Injection Volume Difference Between Each Fuel
Injector

76 to 91 cm3 (4.6 to 5.5 cu in.) per 15 15 cm3 (0.9 cu in.) or less

seconds
A075915E06
NOTICE:
Always do the switching at the battery side.
If the result is not as specified, replace the fuel
injector.
(c) Check the fuel leakage.
(1) When checking the injection volume, remove
SST from the battery. Inspect the fuel leakage
from the fuel injector.
Standard:
1 drop or less every 12 minutes.
FU If the result is not as specified, replace the fuel
injector.
INSTALLATION
1. INSTALL FUEL INJECTOR
New Insulator (a) Install a new insulator onto each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to a new
O-ring and install it onto each fuel injector.

New O-ring
A075654E06

(c) While turning the fuel injector left and right, install it
onto the fuel delivery pipe.
(d) Position the fuel injector connector facing outward.

Connector

Turn

Push
A075655E04

2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Place the fuel delivery pipe together with the 6 fuel
injectors on the intake manifold.
(b) Provisionally install the 6 bolts, which are used to
hold the fuel delivery pipe, onto the intake manifold.
(c) Check that the fuel injectors rotate smoothly.
Turn HINT:
Connector If the fuel injectors do not rotate smoothly, replace
the O-ring.
A075656E03 (d) Position the fuel injector connector facing outward.
1GR-FE FUEL – FUEL INJECTOR FU–17

(e) Tighten the 6 bolts, which are used to hold the fuel
delivery pipe, to the intake manifold.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
(f) Connect the 6 fuel injector connectors.
3. CONNECT FUEL PIPE SUB-ASSEMBLY
(a) Push the tube connector into the pipe until the tube
connector makes a "click" sound.
NOTICE:
• Check if there is any damage or foreign
objects on the connected part of the fuel pipe.
• After connecting, check that the pipe and
connector are securely connected by pulling
them.
(b) Install the fuel pipe clamp.
4. CONNECT NO.1 FUEL PIPE SUB-ASSEMBLY
(a) Push the tube connector into the pipe until the tube
connector makes a "click" sound.
NOTICE:
• Check if there is any damage or foreign
objects on the connected part of the fuel pipe. FU
• After connecting, check that the pipe and
connector are securely connected by pulling
them.
(b) Install the fuel pipe clamp.
5. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket and the intake air surge tank
with the 2 nuts.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
(b) Using an 8 mm socket hexagon wrench, install the 4
bolts.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
(c) Install the 3 upper bolts which are used to secure
the 2 surge tank stays and throttle body bracket.
Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
(d) Install the 3 wire harness clamps and hose clamp.
(e) Connect the throttle motor connector.
(f) Connect the 2 VSV connectors.
(g) Connect the ventilation hose.
(h) Connect the fuel vapor feed hose.
(i) Connect the water by-pass hose No. 4.
(j) Connect the water by-pass hose No. 5.
6. INSTALL AIR CLEANER ASSEMBLY (See page ES-
416)
7. INSTALL V-BANK COVER (See page ES-416)
8. CONNECT CONNECT BATTERY NEGATIVE
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
9. ADD ENGINE COOLANT (See page CO-3)
10. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-4)
 FU–18 1GR-FE FUEL – FUEL INJECTOR

11. CHECK FOR FUEL LEAKAGE

FU