Toyota Avalon, Camry, Camry Solara 2001-06

Fuel Injectors

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Removal & Installation



1MZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable. Work must be started approximately 90 seconds or longer after the negative battery cable has been disconnected, if equipped with an air bag
     
    Accelerator and throttle cables
     
    Air cleaner assembly
     
    V-bank cover
     
    Emission valve control set
     
    No. 2 EGR pipe
     
    Hydraulic motor pressure pipe from the water inlet and air inlet chamber
     
    Air intake chamber assembly
     
    Injector wiring
     
    Air assist pipe from the bracket on the No. 1 fuel pipe
     
    Air assist hoses from the intake manifold
     
    Fuel return hose from the No. 1 fuel pipe
     
    Fuel inlet hose for the fuel filter
     
    2 union bolts holding the No. 2 fuel pipe to the delivery pipes
     
    Fuel return hose from the fuel pressure regulator
     
    Union bolt for the right hand delivery pipe, 2 gaskets, 2 bolts, left hand delivery pipe together with the 3 injectors and the No. 2 fuel pipe
     
    Union bolt for the delivery pipe and 2 gaskets from the No. 2 fuel pipe
     
    The 3 bolts, right hand delivery pipe together with the 3 injectors and the No. 1 fuel pipe
     
    The 4 spacers from the intake manifold
     
    The 6 injectors from the delivery pipes
     
    The two O-rings and two grommets from each injector
     

  8.  

To install:

  1. Install or connect the following:

    2 new grommets to each injector
     
    New O-rings, with a light coat of fuel, to each injector
     
    Injectors
     
    The 4 spacers on the intake manifold
     
    Right hand delivery pipe and the No. 1 fuel pipe together with the 3 injectors in position on the intake manifold
     
    Bolt holding the right side delivery pipe, temporarily, to the intake manifold
     
    Left hand delivery pipe and the No. 2 fuel pipe together with the 3 injectors in position on the intake manifold
     
    Fuel return hose to the fuel pressure regulator
     

  2.  
  3. Temporarily install the 2 bolts holding the left hand delivery pipe to the intake manifold.
  4.  
  5. Temporarily install the No. 2 fuel pipe to the left side delivery pipe with the union bolt and 2 new gaskets.
  6.  
  7. Check that the injectors rotate smoothly. If they do not, Replace the O-rings.
  8.  
  9. Position the injector connector outward. Tighten the 4 bolts holding the delivery pipes to the intake manifold and tighten to 7 ft. lbs. (10 Nm). Tighten the bolt holding the No. 1 fuel pipe to the intake manifold to 14 ft. lbs. (20 Nm). Tighten the 2 union bolts holding the no. 2 fuel pipe to the delivery pipes to 24 ft. lbs. (32 Nm).
  10.  
  11. Install or connect the following:

    Fuel inlet and return hoses. Union bolt: 22 ft. lbs. (30 Nm).
     
    Fuel return hose to the No. 1 fuel pipe. Pass the fuel return hose under the heater hoses
     
    Air assist hoses to the intake manifold
     
    Air assist pipe to the bracket on the No. 1 fuel pipe
     
    Fuel injector wiring connectors
     
    Air intake chamber assembly
     
    Hydraulic motor pressure pipe to the intake chamber. Bolts: 69 inch lbs. (8 Nm)
     
    No. 2 EGR pipe with new gaskets, tighten to 9 ft. lbs. (12 Nm)
     
    Emission control valve set
     
    V-bank cover
     
    Air cleaner hose
     
    Throttle and accelerator cables
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system to the proper level.
  14.  
  15. Start the vehicle and check for leaks.
  16.  

2az-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Engine cover
     
    Fuel tube assembly
     
    Fuel delivery pipe with the injectors
     

  6.  

To install:

  1. Install or connect the following:

    New O-rings, coated with gasoline, on each injector
     
    Injectors into the fuel rail while turning each left and right. After installation, check that the injectors turn freely in place; if not, remove the injector and inspect the O-ring for damage or deformation.
     
    New spacers on the head
     
    Fuel rail and injectors; check that the injectors still turn freely in position. Position the injector connectors outward
     
    Retaining bolts, tightening them to 15 ft. lbs. (20 Nm)
     
    Fuel tube assembly
     
    Air intake assembly
     
    Engine appearance cover.
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks
  4.  

2gr-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the fuel injector components-3.5L (2GR-FE) engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Wiper arm and blades
     
    Top cowl ventilator louver
     
    Wiper motor and linkage assembly
     
    Outer top cowl panel
     
    Engine appearance cover
     
    Air intake assembly
     
    Air intake surge tank
     
    Fuel supply hose
     
    Injector electrical connectors
     
    Fuel rail
     
    Insulators from the intake manifold
     
    Fuel injectors from the fuel rail
     

  8.  

To install:

  1. Apply a light coat of spindle oil or gas to new O-rings. Install the new O-rings to each injector.
  2.  
  3. Apply a light coat of spindle oil or gas where the fuel rail contacts the injector.
  4.  
  5. Push the injector, while turn the injector back and forth to install it in the fuel rail.
  6.  
  7. Install new insulators to the intake manifold.
  8.  
  9. Install the fuel rail and temporarily install the mounting bolts.
  10.  
  11. Check that each injectors turns smoothly. If not, reinstall the injector with a new O-ring.
  12.  
  13. Tighten the fuel rail mounting bolts to 15 ft. lbs. (21 Nm).
  14.  
  15. Install or connect the following:

    Injector electrical connectors
     
    Fuel supply hose
     
    Air intake surge tank. Tighten Bolts B to 13 ft. lbs. (18 Nm); Bolts C to 12 ft. lbs. (16 Nm); Nut to 15 ft. lbs. (21 Nm).

    Click image to see an enlarged view

    Fig. Bolt identification for the air intake surge tank installation-3.5L (2GR-FE) engine

     



    Air intake assembly
     
    Outer top cowl panel
     
    Wiper motor and linkage assembly
     
    Top cowl ventilator louver
     
    Wiper arm and blades
     
    Negative battery cable
     

  16.  
  17. Refill the cooling system to the correct level.
  18.  
  19. Start the engine and check for leaks.
  20.  

3MZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Suspension upper center brace
     
    V-bank cover sub assembly
     
    Air cleaner assembly
     
    Emission control valve set
     

  4.  
  5. Remove intake air surge tank
  6.  
  7. Remove or disconnect the following:

    Throttle motor connector
     
    Water by-pass hoses
     
    Union check valve hose
     
    Ventilation hose
     
    Pressure feed hose
     
    Engine hangers
     
    Surge tank stays
     
    Bond cable connector
     
    Emission control valve bracket
     
    Intake air surge tank

    Click image to see an enlarged view

    Fig. Exploded view of Intake Air Surge tank-3.3L (3MZ-FE) engine

     
    Gasket from intake air surge tank
     

  8.  
  9. Remove fuel pipe assembly
  10.  
  11. Remove or disconnect the following:

    Fuel pulsation damper and gasket
     
    Fuel pipe union bolt and 2 gaskets
     
    Bolt and separate the fuel pipe
     

  12.  
  13. Remove the fuel injector assembly
  14.  
  15. Remove or disconnect the following:
    WARNING
    Be careful not to drop the fuel injectors when removing the fuel delivery pipes.



    6 fuel injector connectors
     
    4 bolts, then remove the fuel injector delivery pipes
     



    4 delivery pipe spacers from intake manifold
     
    6 insulators from the intake manifold
     
    Fuel injector from the fuel delivery pipes.

    Click image to see an enlarged view

    Fig. Exploded view of fuel injector delivery pipe and injectors-3.3L (3MZ-FE) engine

     

  16.  

To install:

  1. Install new fuel injector assembly
  2.  
  3. Install or connect the following
    NOTE
    Check that the injectors rotate smoothly. If the injectors do not rotate smoothly, the probable cause is incorrect installation of the O-rings. Replace the O-rings.



    A new insulator and grommet to each injector
     
    A light coat of gasoline to new O-rings and install them to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning the clockwise and counterclockwise, into the delivery pipe
     
    The 6 insulators and 4 spacers in position on the intake manifold
     
    A light coat of gasoline on the place where an intake manifold touches an O-ring
     
    The delivery pipes in position on the intake manifold
     
    Temporarily, the 4 bolts holding the delivery pipe to the intake manifold
     



    4 bolts. Tighten bolts uniformly. Torque to: 7 ft. lbs. (10 Nm)
     
    6 fuel injector connectors
     

  4.  
  5. Install fuel pipe assembly
  6.  
  7. Install or connect the following

    2 gaskets and fuel pipe union bolt
     
    2 gaskets and fuel pressure pulsation damper
     
    Fuel pipe with bolt
     

  8.  
  9. Install intake air surge tank
  10.  
  11. Install or connect the following

    New gaskets to intake air surge tank
     
    Intake air surge tank and emission control valve bracket. Torque: 21 ft. lbs. (28 Nm).
     
    4 bolts. Torque: 21 ft. lbs. (28 Nm)
     
    2 bolts on surge tank stay. Torque: 21 ft. lbs. (28 Nm).
     
    Engine hangers
     
    Pressure feed tube
     

  12.  
  13. The remainder of the installation is the reverse order of removal.
  14.  
  15. Refill the cooling system to the correct level.
  16.  
  17. Start the engine and check for leaks.
  18.  

5S-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator cable from the throttle body
     
    If equipped with automatic transmission, the throttle cable
     
    Air intake temperature sensor connector
     
    Cruise control actuator cable from the clamp on the resonator
     
    Air cleaner
     
    Wiring from the throttle position sensor and the ISC valve
     
    Hoses from the PCV, EGR vacuum modulator and EVAP VSV
     
    Throttle body
     
    PS vacuum hoses
     
    Hoses from the EVAP Bi-metal Vacuum Switching Valve (BVSV)
     
    EGR valve and the vacuum modulator
     
    Vacuum sensor hose at the air intake chamber
     
    Brake booster vacuum hose and the vacuum sensing hose
     
    With air conditioning, the magnet switch VSV wiring
     
    Ground straps from the intake manifold
     
    Knock sensor and EGR Vacuum Switching Valve (VSV) wiring
     
    Engine wire harness
     
    Stays or supports holding the air intake chamber and the intake manifold
     
    Intake manifold
     
    Wiring from each injector
     
    Fuel inlet pipe
     
    Fuel return hose

    Click image to see an enlarged view

    Fig. Loosening and removing the pulsation damper-2.2L (5S-FE) engine

     
    Delivery pipe or fuel rail along with the injectors

    Click image to see an enlarged view

    Fig. Unbolt and remove the fuel delivery pipe and injectors as an assembly

     
    Insulators and rail spacers from the head
     
    Injectors from the fuel rail
     
    O-ring and grommet from each injector
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    The upper mounting bolts are shorter than the lower mounting bolts. Make certain the bolts are correctly placed before tightening.



    New grommet on each injector
     
    New O-rings, coated with gasoline, on each injector

    Click image to see an enlarged view

    Fig. Place new injector seals and spacers in position on the cylinder head-2.2L (5S-FE) engine shown

     
    Injectors into the fuel rail while turning each left and right. After installation, check that the injectors turn freely in place; if not, remove the injector and inspect the O-ring for damage or deformation.
     
    New insulators and spacers on the head
     
    Fuel rail and injectors; check that the injectors still turn freely in position. Position the injector connectors upward
     
    Retaining bolts, tightening them to 9 ft. lbs. (13 Nm)
     
    Fuel return hose
     
    Fuel inlet pipe and pulsation damper to the delivery pipe. Use new gaskets; tighten the union bolt to 25 ft. lbs. (34 Nm).
     
    Wiring to each injector
     
    Intake manifold. Nuts and bolts evenly in several passes to 14 ft. lbs. (19 Nm).
     
    Air chamber and manifold stays. 14mm bolt: 31 ft. lbs. (42 Nm) and the 12mm bolt to 16 ft. lbs. (22 Nm).
     
    Engine wire harness
     
    Wiring to the knock sensor and the EGR VSV
     
    Both engine ground straps to the intake manifold
     
    A/C magnet switch wiring
     
    Hoses for the vacuum sensor, brake booster and vacuum sensing hose
     
    EGR valve and vacuum modulator. Use new gaskets. Tighten the union nut to 43 ft. lbs. (59 Nm) and the bolt to 9 ft. lbs. (13 Nm).
     
    Hoses to the charcoal canister and EGR VSV
     
    Wiring to the EGR temperature sensor if it was removed
     
    Vacuum hoses to the EVAP BVSV
     
    PS vacuum hoses
     
    Throttle body. Bolts, evenly and alternately, to 14 ft. lbs. (19 Nm).
     



    PCV, EGR vacuum modulator and EGR VSV hoses to the throttle body
     
    Wiring for the throttle position sensor
     
    Air cleaner cap, resonator and intake hose
     
    Wiring to the air intake temperature sensor
     
    Cruise control actuator cable
     
    Throttle control cable
     
    Accelerator cable
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
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