Toyota Tundra 2001-06

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3.4L Engines


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Fig. Fuel injector arrangement and related components-3.4L engine



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Fig. Install new O-rings and grommets on each injector-3.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Depressurize the fuel system.
  4.  
  5. Remove or disconnect the following:

    Air cleaner hose
     
    Upper half of the intake manifold
     
    Fuel pressure regulator
     
    Fuel inlet pipe
     
    Fuel injector electrical connections
     
    Fuel rail with the injectors
     
    Spacers from the intake manifold
     
    Injectors from the delivery pipes
     
    O-rings and grommets, discard them
     

  6.  

To install:

  1. Install or connect the following:

    New grommets and O-rings on each injector, lubricated with a light coat of gasoline
     
    Fuel injector with the electrical connector facing outward
     
    Spacers on the intake manifold
     

  2.  
  3. Temporarily install the bolts to hold the delivery pipes to the intake manifold.
  4.  
  5. Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly.
  6.  
  7. Install or connect the following:

    Fuel injector electrical connectors
     
    Fuel pipe with new gaskets. Tighten the bolts to 25 ft. lbs. (34 Nm) and the delivery pipes-to-intake manifold bolts to 10 ft. lbs. (13 Nm).
     
    Fuel pipe union with new gaskets. Tighten the clamp bolt to 71 inch lbs. (8 Nm).
     
    Fuel pressure regulator
     

  8.  
  9. Inspect the vacuum lines and connections. Look for any loose connections, sharp bends or damage.
  10.  
  11. Install or connect the following:

    Air cleaner
     
    Air cleaner hose
     

  12.  
  13. Start the engine and check for vacuum and fuel leaks.
  14.  

4.0L Engine


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Fig. Fuel injector and related components-4.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant. Remove the V bank cover.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Remove the intake manifold.
  12.  
  13. Disconnect and plug the fuel line hoses.
  14.  
  15. Disconnect the fuel injector connectors. Remove the six bolts and the fuel rail together with the injectors.
  16.  
  17. Pull the injectors out of the fuel rail.
  18.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new gaskets and O-rings, as required.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

4.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine appearance cover
     
    Air intake tube
     
    Fuel lines
     
    Fuel pulsation damper
     
    Fuel pressure regulator vacuum line
     
    Accelerator cable and bracket
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Evaporative Emissions (EVAP) vacuum switching valve
     
    Engine appearance cover brackets
     
    Fuel injector harness connectors
     
    Engine harness protector
     
    Fuel supply manifold crossover pipe
     
    Fuel supply manifolds with injectors attached
     
    Fuel injectors
     

  6.  

To install:

  1. Install the fuel injectors to the supply manifold with new O-ring seals and new grommets.
  2.  
  3. Install new injector insulators to the intake manifold.
  4.  
  5. Install or connect the following:

    Fuel supply manifolds with injectors attached. Tighten the bolts to 66 inch lbs. (7.5 Nm).
     
    Fuel supply manifold crossover pipe. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Engine harness protector
     
    Fuel injector harness connectors
     
    Engine appearance cover brackets
     
    EVAP vacuum switching valve
     
    PCV valve and hose
     
    Accelerator cable and bracket
     
    Fuel pressure regulator vacuum line
     
    Fuel pulsation damper
     
    Fuel lines
     
    Air intake tube
     
    Engine appearance cover
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the throttle body cover subassembly. Remove the air cleaner assembly.
  8.  
  9. Remove the fuel pressure pulsation damper, upper gasket, fuel main hose and lower gasket.
  10.  
  11. Disconnect the PCV hose. Disconnect the VSV connector at the EVAP. Disconnect the EVAP hose. Remove the VSV for the EVAP from the intake manifold.
  12.  
  13. Remove the throttle body cover bracket.
  14.  
  15. Disconnect the engine wire clamps from the number one engine hanger and engine wire bracket.
  16.  
  17. Disconnect the two wire clamps on the engine wire from the brackets on the right delivery line.
  18.  
  19. Disconnect and plug the fuel line hoses.
  20.  
  21. Disconnect the fuel injector connectors. Remove the bolts and the fuel rail together with the injectors.
  22.  
  23. Remove the injectors from the fuel rail. Remove the O-ring, grommet and insulator.
    NOTE
    Do not apply any load to the injector in the horizontal direction.

  24.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new gaskets and O-rings, as required.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

 
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