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Toyota Celica, Corolla, ECHO & MR2 1999-05

Fuel Injectors 1

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Removal & Installation



A small amount of gasoline will be needed to install the O-rings on the injectors. Only replace injectors with NEW insulators and O-rings! If inserting an injector, and it does not seat properly, a new O-ring will be necessary to reinsert the injector.

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

    Negative battery cable
     
    Cylinder head cover
     
    Fuel pipe clamp
     
    Fuel inlet line from the fuel pipe
     
    Injector connectors from the injectors
     
    Delivery pipe (3 bolts) and injectors
     
    2 spacers from the head
     
    Injectors from the pipe
     
    O-rings and grommets
     

  4.  

To install:

  1. Install or connect the following:

    New grommets
     
    New O-rings coated with clean engine oil
     
    Injectors to the pipe. Coat the contact area with light machine oil. The injectors twist into place. The connector should face outward
     
    Delivery pipe bolts. Torque: 14 ft. lbs. (19 Nm).
     
    Fuel pipe bolt. Torque: 80 inch lbs. (9 Nm).
     
    Fuel hose to fuel pipe
     
    Pipe clamp
     
    Wire harness cover
     
    PCV hose
     
    Negative battery cable
     

  2.  

1ZZ-FE Engines
  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:

    No. 2 cylinder head cover
     
    PCV hose
     
    Fuel tube from the fuel pipe
     
    Injector connectors
     
    Delivery pipe and injectors
     
    Spacers from the head
     
    Injectors from the delivery pipe
     
    O-ring and grommet from each injector

    Click image to see an enlarged view

    Fig. Fuel injector removal and installation-1ZZ-FE engine

     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Coat the contact point on the pipe with light machine oil and twist the injectors into place. The connector should face outward.


    NOTE
    Coat the seats in the head where the injectors contact, with light machine oil.



    New grommets
     
    New O-rings coated with light machine oil
     
    Injectors on the delivery pipe
     



    Spacers
     



    Delivery pipe and injectors
     

  2.  
  3. Loosely install the hold-down bolts and check that the injectors rotate smoothly. If they don-t, the probable cause is incorrect O-ring installation.
  4.  
  5. Torque the hold-down bolts to 14 ft. lbs. (19 Nm).
  6.  
  7. Torque the fuel pipe bolt to 84 inch lbs. (9 Nm).
  8.  
  9. Connect the fuel line.
  10.  
  11. Install the PCV hose.
  12.  
  13. Install the No. 2 cover.
  14.  

  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 cleaner
     
    Accelerator cable bracket from the throttle body
     
    Throttle body from the air intake chamber
     
    Engine hanger and air intake chamber stay
     
    EGR vacuum modulator if so equipped
     
    EGR valve and pipe if so equipped
     
    Air intake chamber cover and gasket
     
    Injector electrical connections
     
    Fuel inlet hose from the delivery pipe
     
    Fuel return hose from the fuel pressure regulator
     
    Fuel delivery pipe (rail)
     
    The 4 insulators and 2 collars from the intake manifold
     
    Injectors
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Before installing the injectors back into the fuel rail, install a NEW O-ring on each injector, coated with a light coat of gasoline (NEVER use oil of any sort).


    NOTE
    Make certain each injector can be smoothly rotated. If they do not rotate smoothly, the O-ring is not in its correct position.






    Injectors
     



    Insulators into each injector hole
     
    The two spacers on the delivery pipe mounting holes in the intake manifold
     

  2.  
  3. Place the delivery pipe and injectors on the intake manifold and again check that the injectors rotate smoothly. Position the injector connector upward. Install the two bolts and tighten them to 11 ft. lbs.
  4.  
  5. Install or connect the following:

    Electrical connectors to each injector
     
    Gaskets, the inlet pipe and fuel union bolt. Bolt to 22 ft. lbs.
     
    Air intake chamber cover with a NEW gasket. Torque the retaining bolts in steps to 14 ft. lbs.
     
    All necessary hoses and electrical connections
     
    EGR valve and pipe if so equipped
     
    Engine hanger and air intake chamber stay
     
    EGR vacuum modulator if so equipped
     
    Throttle body. Torque the bolts evenly (in a X-pattern) to 16 ft. lbs.
     
    Accelerator cable bracket to the throttle body
     
    Air cleaner hose and cap
     
    Negative battery cable
     

  6.  

2ZZ-GE Engines
  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:

    No. 2 cylinder head cover
     
    Fuel tube from the fuel pipe
     
    Injector connectors
     
    Delivery pipe and injectors
     
    Spacers from the head
     
    Injectors from the delivery pipe
     
    O-ring and grommet from each injector

    Click image to see an enlarged view

    Fig. Fuel injector removal and installation-2ZZ-GE engine

     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Coat the contact point on the pipe with light machine oil and twist the injectors into place. The connector should face outward.


    NOTE
    Coat the seats in the head where the injectors contact, with light machine oil.



    New grommets
     
    New O-rings coated with light machine oil
     
    Injectors on the delivery pipe
     



    Spacers
     



    Delivery pipe and injectors
     

  2.  
  3. Loosely install the hold-down bolts and check that the injectors rotate smoothly. If they don-t, the probable cause is incorrect O-ring installation.
  4.  
  5. Torque the hold-down bolts to 21 ft. lbs. (29 Nm).
  6.  
  7. Torque the fuel pipe bolt to 84 inch lbs. (9 Nm).
  8.  
  9. Connect the fuel line.
  10.  
  11. Install the PCV hose.
  12.  
  13. Install the No. 2 cover.
  14.  

5S-FE Engine


Click image to see an enlarged view

Fig. View of the fuel injector, delivery pipe and related components-5S-FE engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner cap and hose
     
    Throttle body assembly
     
    Valve cover assembly
     
    Vacuum sensing hose from the fuel pressure regulator
     
    Air hose from the air assist system at the intake manifold port
     
    Engine wire protector from the left side of the intake manifold
     
    Injector wiring
     
    Engine wiring protector from the 2 brackets on the front of the intake manifold
     
    Union bolt, 2 gaskets, and the fuel inlet hoses from the delivery pipe
     
    Fuel return hose from the return pipe
     
    Delivery pipe from the cylinder head
     
    Delivery pipe from the 4 injectors and extract the pipe
     
    Injectors from the pipe
     
    4 insulators and 2 spacers from the intake manifold
     
    The 2 O-rings, insulator and grommet from each injector
     
    The O-ring and grommet from each injector

    Click image to see an enlarged view

    Fig. The California fuel injector has 2 O-rings a insulator and grommet



    Click image to see an enlarged view

    Fig. View of the non-California fuel injector

     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Position each injector in with the connector facing upward.



    New insulator and grommet on each injector
     
    New grommet on each insulator
     
    O-ring(s) on each injector

    Click image to see an enlarged view

    Fig. The correct way to install a new fuel injector O-ring

     
    Spacers and insulators to the intake manifold
     
    Delivery pipe between the intake manifold and cylinder head
     
    Injectors into the delivery pipe

    Click image to see an enlarged view

    Fig. When inserting the injector, turn left and right making sure the connector is facing upward



    Click image to see an enlarged view

    Fig. The injector will seat in the fuel rail and intake manifold as shown

     



    Delivery pipe assembly to the cylinder head
     

  2.  
  3. Temporarily install the bolts holding the pipe to the cylinder head. Check that the injectors rotate smoothly. If they do not rotate smoothly, the O-ring(s) may have been install incorrectly. Replace the O-ring if this occurs.

    Click image to see an enlarged view

    Fig. Once the injector is in check for it to rotate smoothly

  4.  
  5. Install or connect the following:
    NOTE
    Be careful of the fuel inlet hose installation direction.


    NOTE
    The No. 1 and No. 3 injector wiring are brown and the No. 2 and No. 4 are gray.



    Delivery pipe retaining bolts: 9 ft. lbs. (13 Nm).
     
    Fuel inlet hose to the delivery pipe with new gaskets and union bolt. Tighten the assembly to 25 ft. lbs. (34 Nm).
     



    Click image to see an enlarged view

    Fig. Place the fuel inlet hose on in the correct direction



    Fuel return hose to the return pipe
     
    Engine wire protector to the brackets on the front side of the intake manifold
     
    Injector wiring harnesses
     



    Engine wire protector to the left side of the intake manifold
     
    Vacuum sensing hose to the fuel pressure regulator
     
    Air hose for the air assist system to the intake manifold port
     
    Valve cover assembly
     
    Throttle body
     
    Control cables to the throttle body
     
    Air cleaner cap and hose
     
    Negative battery cable
     

  6.  



Click image to see an enlarged view

Fig. View of the fuel injector, delivery pipe and related components-5S-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 cleaner cap and hose
     
    Throttle body assembly
     
    Valve cover assembly
     
    Vacuum sensing hose from the fuel pressure regulator
     
    Air hose from the air assist system at the intake manifold port
     
    Engine wire protector from the left side of the intake manifold
     
    Injector wiring
     
    Engine wiring protector from the 2 brackets on the front of the intake manifold
     
    Union bolt, 2 gaskets, and the fuel inlet hoses from the delivery pipe
     
    Fuel return hose from the return pipe
     
    Delivery pipe from the cylinder head
     
    Delivery pipe from the 4 injectors and extract the pipe
     
    Injectors from the pipe
     
    4 insulators and 2 spacers from the intake manifold
     
    The 2 O-rings, insulator and grommet from each injector
     
    The O-ring and grommet from each injector

    Click image to see an enlarged view

    Fig. The California fuel injector has 2 O-rings a insulator and grommet



    Click image to see an enlarged view

    Fig. View of the non-California fuel injector

     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Position each injector in with the connector facing upward.



    New insulator and grommet on each injector
     
    New grommet on each insulator
     
    O-ring(s) on each injector

    Click image to see an enlarged view

    Fig. The correct way to install a new fuel injector O-ring

     
    Spacers and insulators to the intake manifold
     
    Delivery pipe between the intake manifold and cylinder head
     
    Injectors into the delivery pipe

    Click image to see an enlarged view

    Fig. When inserting the injector, turn left and right making sure the connector is facing upward



    Click image to see an enlarged view

    Fig. The injector will seat in the fuel rail and intake manifold as shown

     



    Delivery pipe assembly to the cylinder head
     

  2.  
  3. Temporarily install the bolts holding the pipe to the cylinder head. Check that the injectors rotate smoothly. If they do not rotate smoothly, the O-ring(s) may have been install incorrectly. Replace the O-ring if this occurs.

    Click image to see an enlarged view

    Fig. Once the injector is in check for it to rotate smoothly

  4.  
  5. Install or connect the following:
    NOTE
    Be careful of the fuel inlet hose installation direction.


    NOTE
    The No. 1 and No. 3 injector wiring are brown and the No. 2 and No. 4 are gray.



    Delivery pipe retaining bolts: 9 ft. lbs. (13 Nm).
     
    Fuel inlet hose to the delivery pipe with new gaskets and union bolt. Tighten the assembly to 25 ft. lbs. (34 Nm).
     



    Click image to see an enlarged view

    Fig. Place the fuel inlet hose on in the correct direction



    Fuel return hose to the return pipe
     
    Engine wire protector to the brackets on the front side of the intake manifold
     
    Injector wiring harnesses
     



    Engine wire protector to the left side of the intake manifold
     
    Vacuum sensing hose to the fuel pressure regulator
     
    Air hose for the air assist system to the intake manifold port
     
    Valve cover assembly
     
    Throttle body
     
    Control cables to the throttle body
     
    Air cleaner cap and hose
     
    Negative battery cable
     

  6.  

7A-FE Engine
  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. View of the fuel injector, fuel rail and related components-7A-FE engine

  1. Remove the air cleaner cap and air hose.
  2.  
  3. Disconnect the accelerator cable bracket from the throttle body.
  4.  
  5. Disconnect the throttle body from the air intake chamber.
  6.  
  7. If necessary, remove the engine hanger, air intake chamber stay and EGR vacuum modulator. Refer to Section 3 and Section 4.
  8.  
  9. If equipped, remove the EGR valve and pipe.
  10.  
  11. Remove the air intake chamber cover. Disconnect and label all hoses and wiring incorporated with the removal.
  12.  

A 6mm hexagon wrench will be necessary to remove the air intake chamber cover bolts.

  1. Unplug the injector wiring.
  2.  
  3. Slowly loosen and remove the union bolt and two gaskets, the disconnect the inlet hose from the delivery pipe. Place s suitable container or shop towel under the pipe to catch any split fuel.
  4.  
  5. Disconnect the fuel return hose from the pressure regulator.
  6.  



Click image to see an enlarged view

Fig. Unbolt the fuel inlet hose by loosening the union bolt, then ...



Click image to see an enlarged view

Fig. ... remove the return hose from the pressure regulator at the other end of the fuel rail

  1. Unbolt the fuel rail together with the four injectors.
  2.  



Click image to see an enlarged view

Fig. Remove the bolts attaching the fuel rail to the intake manifold

Be careful NOT to drop the injectors when removing the fuel rail.



Click image to see an enlarged view

Fig. Lift the fuel rail carefully so the injectors do NOT fall out

  1. Remove the four insulators and two spacers from the intake manifold.
  2.  



Click image to see an enlarged view

Fig. An insulator is located at the tip of the injector

  1. Pull out the four injectors from the delivery pipe.
  2.  



Click image to see an enlarged view

Fig. Pull each injector from the fuel rail, try not to mix them up

  1. Remove the O-ring and grommet from each injector.
  2.  



Click image to see an enlarged view

Fig. From each injector, remove the grommet and O-ring

To install:

  1. Install a new grommet on each injector.
  2.  
  3. Apply a light coat of gasoline to the new O-ring and install it to the injector.
  4.  
  5. While turning the injector left and right, install it to the delivery pipe. Install each injector in the same manner.
  6.  
  7. Position the injector wiring connector upward.
  8.  
  9. Place new insulators and spacers in position on the intake manifold.
  10.  
  11. Place the injectors and delivery pipe assembly in position on the intake manifold.
  12.  
  13. Check the injectors rotate smoothly.
  14.  

If the injectors do not rotate smoothly, the O-rings were probably not installed correctly. Remove the injector and install a new O-ring, then reinsert the injector.

  1. Position the injector connector upward.
  2.  
  3. Tighten the bolts holding the delivery pipe to the intake manifold. Secure the bolts to 11 ft. lbs. (15 Nm).
  4.  
  5. Connect the fuel return hose to the pressure regulator.
  6.  
  7. Attach the fuel inlet hose with the two gaskets and union bolt and secure to 22 ft. lbs. (29 Nm).
  8.  
  9. Attach the injector connectors.
  10.  
  11. Install the air intake chamber cover. Secure the bolts in the correct sequence.
  12.  



Click image to see an enlarged view

Fig. Air intake chamber cover bolt tightening sequence

  1. If removed, install the EGR valve and pipe.
  2.  
  3. If removed, attach the air intake chamber stay, EGR vacuum modulator and engine hanger.
  4.  
  5. Install the throttle body. Refer to the procedure in this section.
  6.  
  7. Connect the accelerator cable bracket to the throttle body.
  8.  
  9. Attach the air cleaner cap and hose.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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