Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

Fuel Rail and Injectors

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REMOVAL & INSTALLATION



The engines covered by this information are Sequentially Fuel Injected (SFI). This requires that the electrical connectors for each injector be tagged so that they can be installed in their exact original locations. This is extremely important.

1FZ-FE Engine

Like most multi-port fuel injected engines, the fuel injectors are mounted on a fuel rail (Toyota calls it a "delivery pipe"). On this engine, the fuel rail is hidden under the upper half of the intake manifold, which must be removed to access the injectors. At assembly, a new intake manifold gasket will be required. Use care when working around light alloy parts. Numerous hose connections must be detached. Identify and tag these hoses as required.



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Fig. Fuel injector arrangement and related components1997 Land Cruiser with 1FZ-FE engine



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Fig. The injectors are removed with the fuel rail (delivery pipe)1997 Land Cruiser with 1FZ-FE engine



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Fig. Install a new grommet and lubricated O-ring on the injector1997 Land Cruiser with 1FZ-FE engine



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Fig. Install each injector to the fuel rail by pushing while twisting the injector1997 Land Cruiser with 1FZ-FE engine



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Fig. Place new insulators and spacers in the positions indicated1997 Land Cruiser with 1FZ-FE engine



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Fig. Rotate the injectors to ensure smooth movement. An injector that binds has been improperly installed and may leak1997 Land Cruiser with 1FZ-FE engine

  1. Relieve the fuel system pressure.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Remove the upper half of the intake manifold. For additional information, please refer to the following topic(s): "ENGINE AND ENGINE OVERHAUL," "Intake Manifold."
  6.  
  7. Remove the two union bolts, gaskets and fuel inlet pipe.
  8.  
  9. Remove the delivery pipe and injectors as follows:
    1. Unsecure the six injector connectors.
    2.  
    3. Remove the bolts and delivery pipe together with the six injectors. Be careful not to drop the injectors when removing the pipe.
    4.  
    5. Remove the insulators and spacers on the intake manifold.
    6.  
    7. Pull the injectors out of the delivery pipe. Remove the O-rings and grommets from each injector.
    8.  

  10.  
  11. Inspect the injectors.
  12.  

To install:

  1. Install new grommets on each injector then lubricate the new O-rings with a light coat of gasoline. Install the O-rings to the fuel injectors.
  2.  
  3. While turning the injector left and right to ease it into place, install it to the delivery pipe. Install all 6 injectors.
  4.  
  5. Position the injector connector upward. Place new insulators and spacers in position on the intake manifold.
  6.  
  7. Temporarily install the bolts holding the delivery pipe to the intake manifold.
  8.  
  9. Check that the injectors rotate smoothly. If they do not, recheck the position of the O-rings, or replace them.
  10.  
  11. Position the injector connector upward, then tighten the bolts holding the delivery pipe to the intake manifold to 15 ft. lbs. (21 Nm).
  12.  
  13. Attach the injector connectors taking note of the identification tags made at removal.
  14.  
  15. Install the fuel inlet pipe with new gaskets; tighten the union bolt to 22 ft. lbs. (29 Nm) and the bolt to 14 ft. lbs. (20 Nm).
  16.  
  17. Install the fuel return pipe with the bolts and tighten to 14 ft. lbs. (20 Nm).
  18.  
  19. Attach the hose to the pressure regulator.
  20.  
  21. Install the upper intake manifold.
  22.  
  23. Connect the throttle, accelerator and cruise control actuator cables.
  24.  
  25. Attach the air cleaner and PCV hoses.
  26.  
  27. Fill the cooling system with a water/coolant mixture. Start the engine and add coolant as required. Check for coolant, vacuum and fuel leaks.
  28.  

2RZ-FE and 3RZ-FE Engines


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Fig. Fuel injector arrangement and related components2RZ-FE and 3RZ-FE engines

  1. Relieve the fuel system pressure.
  2.  
  3. Remove the throttle body using the procedures found in this section.
  4.  
  5. Tag the fuel injector electrical connectors for identification to their original locations. Detach the four fuel injector electrical connectors, the Crankshaft Position (CKP) sensor connector, and the Knock Sensor (KS) connector.
  6.  
  7. Detach the DLC1 diagnostic connector and wire clamp from the brackets.
  8.  
  9. Disconnect the vacuum line from the fuel pressure regulator. Detach the fuel return hose from the pressure regulator.
  10.  
  11. Remove the union bolt and gaskets and disconnect the fuel inlet pipe from the fuel rail (delivery pipe). Expect fuel to run out. Place clean shop cloths under the fuel inlet and loosen the bolt slowly.
  12.  
  13. Remove the two fuel rail hold-down bolts and remove the fuel rail with the injector still attached. The injectors are only retained by their O-rings and will tend to drop out of the fuel rail, so use care. Remove the four insulator from the four spacers.
  14.  
  15. Pull out the injectors from the fuel rail. Discard the O-ring and grommet from each injector.
  16.  

To install:

  1. Install new grommets on each injector, and then lubricate the new O-rings with a light coat of gasoline. Install the O-rings to the fuel injectors.
  2.  
  3. While turning the injector left and right to ease it into place, install it to the delivery pipe. Install all four injectors.
  4.  
  5. Position the injector connector upward. Place the new insulators and spacers in position on the intake manifold.
  6.  
  7. Temporarily install the bolts holding the delivery pipe to the intake manifold.
  8.  
  9. Check that the injectors rotate smoothly. If they do not, recheck the position of the O-rings, or replace them.
  10.  
  11. Position the injector connector upward, then tighten the bolts holding the delivery pipe to the intake manifold to 15 ft. lbs. (21 Nm).
  12.  
  13. Attach the injector connectors taking note of the identification tags made at removal.
  14.  
  15. Install the fuel inlet pipe with new gaskets; tighten the union bolt to 22 ft. lbs. (29 Nm) and the bolt to 14 ft. lbs. (20 Nm).
  16.  
  17. Install the fuel return pipe to the fuel pressure regulator. Connect the vacuum line to the pressure regulator.
  18.  
  19. Attach all electrical connectors and vacuum lines, as required.
  20.  
  21. Install the throttle body using the procedures found in this section.
  22.  

5VZ-FE Engine


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Fig. View of a common Toyota style fuel injector



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Fig. Exploded view of the fuel injector arrangement and related components5VZ-FE engine



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Fig. Use a pick to remove the old O-rings. You should always install new O-rings and grommets on each injector prior to installing them



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Fig. While twisting the injector clockwise and counterclockwise, push it into its delivery pipe5VZ-FE engine



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Fig. Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly5VZ-FE engine



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Fig. Temporarily install the union with new gaskets, then connect the fuel pipe. Install the clamp bolt and tighten to 71 inch lbs. (8 Nm)

  1. Relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner hose.
  4.  
  5. Remove the upper half of the intake manifold (Toyota calls it the "Air Intake Chamber"). For additional information, please refer to the following topic(s): "ENGINE AND ENGINE OVERHAUL," "Intake Manifold."
  6.  
  7. Remove the fuel pressure regulator.
  8.  
  9. Disconnect the fuel inlet pipe. Be prepared to collect spilled fuel. Use clean shop cloths under the fuel connection.
  10.  
  11. Tag each of the fuel injector connections for identification to its original location. Detach the fuel injector electrical connections.
  12.  
  13. Unbolt and remove the fuel rail (delivery pipes) together with the injectors.
  14.  
  15. Remove the spacers from the intake manifold.
  16.  
  17. Pull the injectors out of the delivery pipes, and then remove the O-rings and grommets from each injector.
  18.  

To install:

  1. Install new grommets and O-rings on each injector. Apply a light coat of gasoline on the O-rings.
  2.  
  3. While gently twisting the injector clockwise and counterclockwise, push it into the delivery pipe. Install all of the injectors in the same manner.
  4.  
  5. Position the injector connector outward.
  6.  
  7. Place the spacers into position on the intake manifold. Temporarily install the bolts to hold the delivery pipes to the intake manifold.
  8.  
  9. Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly. If this has occurred, replace the O-rings with new ones.
  10.  
  11. Position the injector connector outward, and then attach the injector connectors.
  12.  
  13. Install the fuel pipe with new gaskets and union bolts, tighten to 25 ft. lbs. (34 Nm). Tighten the bolts retaining the delivery pipes to the intake manifold to 10 ft. lbs. (13 Nm).
  14.  
  15. Temporarily install the union with new gaskets, then connect the fuel pipe. Install the clamp bolt; tighten to 71 inch lbs. (8 Nm).
  16.  
  17. Install the fuel pressure regulator.
  18.  
  19. Inspect the vacuum lines and connections. Look for any loose connections, sharp bends or damage.
  20.  
  21. Install the intake air cleaner.
  22.  
  23. Attach the air cleaner hose.
  24.  
  25. Start the engine and check for vacuum and fuel leaks.
  26.  

2UZ-FE Engine


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Fig. Fuel injector arrangement and related components2UZ-FE engine



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Fig. Install the injectors, twisting slightly to seat them. Align the injector electrical connectors as shown2UZ-FE engine

  1. Remove the acoustic/cosmetic throttle body cover.
  2.  
  3. Remove the intake air connector.
  4.  
  5. Remove the fuel pressure pulsation damper, upper gasket and main fuel hoses and its gasket. Expect fuel to run out, so place a clean shop cloth under the connections before loosening the damper.
  6.  
  7. Remove the accelerator cable then remove the two retaining nuts from the bracket.
  8.  
  9. Disconnect the PCV hose from the PCV valve.
  10.  
  11. Detach the electrical connector from the Vacuum Switch Valve (VSV) for the EVAP system. Disconnect the EVAP hose. Remove the accelerator cable clamp and EVAP VSV from the intake manifold.
  12.  
  13. Disconnect the DLC1 diagnostic connector from the throttle body cover bracket then remove the bolt and cover bracket.
  14.  
  15. Tag the wiring harness connections for identification, as required. Then, detach the engine wiring harness clamps from the engine brackets.
  16.  
  17. Remove the bolt holding the clamp on the fuel return pipe to the left side delivery pipe. Remove the bolts from the front fuel pipe (crossover fuel line).
  18.  
  19. Tag each of the fuel injector electrical connectors for identification to their original location. This is important. This engine is sequentially fuel injected and each injector connector must go on the proper fuel injector. Detach the eight fuel injector connectors.
  20.  
  21. Remove the four nuts holding the fuel rails (Toyota calls them "Delivery Pipes") to the lower intake manifold.
  22.  
  23. Remove the fuel rails along with the fuel injectors, the four spacers and eight insulators. Use care. The fuel injectors are retained only by their O-rings and tend to drop out of the fuel rail as it is being removed. Be careful not to drop any injectors.
  24.  

To install:

  1. Install new grommets and O-rings on each injector. Apply a light coat of gasoline on the O-rings.
  2.  
  3. While gently twisting the injector clockwise and counterclockwise, push it into the delivery pipe. Install all eight injectors in this manner.
  4.  
  5. Position the injector connector outward so it will match up with the injector harness connectors.
  6.  
  7. Place the four spacers into position on the intake manifold. Temporarily install the four nuts to hold the fuel rails to the intake manifold.
  8.  
  9. Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly. If this has occurred, replace the O-rings with new ones.
  10.  
  11. Attach the injector connectors, noting the identification tags made at removal.
  12.  
  13. Install the front fuel pipe (crossover) with new gaskets and union bolts, tighten the union bolts to 29 ft. lbs. (39 Nm). Tighten the nuts retaining the fuel rails to the intake manifold to 13 ft. lbs. (18 Nm).
  14.  
  15. If removed, install the fuel pressure regulator.
  16.  
  17. Connect the engine wiring harness to its clamps and brackets. Make sure the wire protector is in place.
  18.  
  19. Connect the PCV hose to the PCV valve.
  20.  
  21. Connect the EVAP VSV to the upper intake manifold.
  22.  
  23. Install the throttle body cover bracket and the DLC1 connector.
  24.  
  25. Install the accelerator cable bracket and tighten the nuts to 13 ft. lbs. (18 Nm).
  26.  
  27. Connect the accelerator cable.
  28.  
  29. Thread the fuel pressure pulsation damper into place and tighten to 29 ft. lbs. (39 Nm).
  30.  
  31. Install the intake air connector and acoustic/cosmetic throttle body cover.
  32.  
  33. Start the engine and check for vacuum and fuel leaks.
  34.  

TESTING



Correct testing of the fuel injectors requires specific equipment not usually available outside a dealership or a fuel lab. It is recommended that any checking or testing of the injectors, other than that included below, be left to a properly equipped service facility.

Injector operation can be checked with the injectors installed in the engine. A "sound scope" is needed here. This is a stethoscope-like device available from most auto tool and parts jobbers.



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Fig. A "sound scope" is usually used to inspect injector operation. Listen for a regular clicking sound as the engine is running



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Fig. If a "sound scope" is not available, check injector operation by feeling for the regular vibrations indicating the injector solenoid is opening and closing

With the engine running or cranking, check each injector for normal operating noise (a clicking, buzzing or humming), which changes in proportion to engine rpm. If a mechanic's stethoscope is not available to you, check injector operation by touching each injector with your finger. It should be buzzing or vibrating indicating the injector solenoid is opening and closing. If no sound or an unusual sound is heard, check the wiring connector, or have the injector checked professionally.

With the engine OFF , measure injector resistance by unplugging the wiring connector from the injector, and connecting an ohmmeter across the injector terminals. Check the continuity at both terminals. Resistance at room temperature should be 1216 ohms. Resistance will vary with injector temperature.



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Fig. An ohmmeter is used to check injector resistance

 
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