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Home >> Toyota >> 1997 >> Supra Liftback L6-2997cc 3.0L DOHC MFI >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Injector >> Service and Repair

Fuel Injector: Service and Repair





COMPONENTS FOR REMOVAL AND INSTALLATION

INJECTORS REMOVAL

1. DRAIN ENGINE COOLANT
2. DISCONNECT CONTROL CABLES FROM THROTTLE BODY
3. REMOVE INTAKE AIR CONNECTOR PIPE
4. REMOVE VSV FOR FUEL PRESSURE CONTROL





(a) Disconnect the connector and hoses:
(1) VSV connector
(2) Vacuum sensing hose from fuel pressure regulator
(3) Vacuum sensing hose from air intake chamber
(b) Remove the bolt and VSV.

EGR Pipe Removal:





5. REMOVE EGR PIPE
(a) Loosen the union nut of the EGR pipe.
(b) Remove the 2 bolts, EGR pipe and gasket.





6. DISCONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR
(a) Disconnect the connector from the No.2 vacuum pipe.
(b) Disconnect the sensor connector from the wiring connector.
7. DISCONNECT NO.2 VACUUM PIPE AND VSV ASSEMBLY
Remove the 2 nuts and disconnect the vacuum pipe from the air intake chamber and intake manifold.





8. DISCONNECT THROTTLE BODY BRACKET FROM THROTTLE BODY AND CYLINDER HEAD.
Remove the 4 nuts and disconnect the throttle body bracket from the throttle body and cylinder head.
9. REMOVE THROTTLE BODY AND INTAKE AIR CONNECTOR ASSEMBLY





(a) Disconnect these connectors and hoses:
(1) Throttle position sensor connector
(2) IAC valve connector
(3) VSV connector for EGR
(4) PCV hose from intake air connector
(5) Water bypass hose (from No.2 water bypass pipe) from throttle body
(6) Air hose from IAC valve

Intake Air Connector Removal:





(b) Remove the nut holding the VSV for the EGR to the air intake chamber.
(c) Remove the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber.





(d) Disconnect these hoses and remove the throttle body, intake air connector assembly and gasket.
(1) 3 vacuum hoses (from No.2 vacuum pipe) from No.1 vacuum pipe
(2) Water bypass hose (from water outlet) from throttle body
(3) Vacuum hose (from actuator for ACIS) from No.1 vacuum pipe





10. REMOVE AIR INTAKE CHAMBER STAYS
(a) Remove the bolt, nut and No.1 stay.
(b) Remove the bolt, nut and No.2 stay.





11. DISCONNECT FUEL INLET PIPE FROM DELIVERY PIPE
Remove the union bolt and 2 gaskets and disconnect the inlet pipe from the delivery pipe.

CAUTION:
- Put a shop towel under the delivery pipe.
- Slowly loosen the union bolt.

12. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR
Remove the union bolt and 2 gaskets and disconnect the fuel pipe from the pressure regulator.

CAUTION:
- Put a shop towel under the pressure regulator.
- Slowly loosen the union bolt.





13. DISCONNECT INJECTOR CONNECTORS
Disconnect the 6 injector connectors.
14. DISCONNECT ACTUATOR FOR ACIS FROM AIR INTAKE CHAMBER

ACIS Actuator Removal:





(a) Remove the 2 bolts and disconnect the actuator from the air intake chamber.





(b) Wrap the actuator with adhesive tape and attach it to the intake chamber.

NOTICE: Do not apply any force on the actuator rod and prevent the rod clip from detaching.

Fuel Delivery Pipe Removal:





15. REMOVE DELIVERY PIPE AND INJECTORS
(a) Remove the 3 bolts and delivery pipe together with the 6 injectors.

NOTICE: Be careful not to drop the injectors when removing the delivery pipe.

(b) Remove the 3 spacers from the intake manifold.
(c) Pull out the 6 injectors from the delivery pipe.
(d) Remove the 2 O-rings, insulator and grommet from each injector.

INJECTORS INSTALLATION

1. INSTALL INJECTORS AND DELIVERY PIPE

Fuel Injector Insulator And O-Ring Installation:





(a) Install new insulator and grommet to each injector.
(b) Apply a light coat of gasoline to 2 new O-rings and install them to each injector.





(c) While turning the injector clockwise and counterclockwise, push it to the delivery pipe, install the 6 injectors.
(d) Position the injector connector outward.





(e) Place the 3 spacers in position on the intake manifold.
(f) Install the 3 bolts to the delivery pipe.
(g) Apply a light coat of gasoline to O-ring on each injector.
(h) Attach the 6 injectors together with the delivery pipe to the intake manifold.
(i) Temporarily install the 3 bolts holding the delivery pipe to the intake manifold.
(j) Check that the injectors rotate smoothly.

HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.





(k) Position the injector connector upward.
(l) Tighten the 3 bolts holding the delivery pipe to the intake manifold.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)

2. INSTALL ACTUATOR FOR ACIS
(a) Install the actuator with the 2 bolts.

Torque: 6.8 N.m (70 kgf.cm, 61 in.lbf)

(b) Inspect the intake air control valve.





3. CONNECT INJECTOR CONNECTORS
Connect the 6 injector connectors.

HINT: The No.1, No.3 and No.5 injector connectors are dark gray and the No.2, No.4 and No.6 injector connectors are gray.

4. CONNECT FUEL INLET PIPE TO DELIVERY PIPE
Connect the inlet pipe with 2 new gaskets and the union bolt.

Torque: 41 N.m (420 kgf.cm, 30 ft.lbf)

5. CONNECT FUEL RETURN PIPE TO FUEL PRESSURE REGULATOR
Connect the return pipe with 2 new gaskets and the union bolt.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)





6. INSTALL AIR INTAKE CHAMBER STAYS

HINT: The No.1 stay is marked with "F" and No.2 stay is marked with "R".

(a) Install the No.1 stay with the bolt and nut.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

(b) Install the No.2 stay with the bolt and nut.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

7. INSTALL THROTTLE BODY AND INTAKE AIR CONNECTOR ASSEMBLY





(a) Install a new gasket to the air intake chamber, facing the protrusion rearward.
(b) Place the throttle body and intake air connector assembly on the cylinder head.
(c) Connect these hoses:
- 3 vacuum hoses (from No.2 vacuum pipe) to No.1 vacuum pipe
- Water bypass hose (from water outlet) to throttle body
- Vacuum hose (from actuator for ACIS) to No.1 vacuum pipe
(d) Install the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)

(e) Install the nut holding the VSV for the EGR to the air intake chamber.
(f) Connect these connectors and hoses:
- Throttle position sensor connector
- IAC valve connector
- VSV connector for EGR
- PCV hose to intake air connector
- Water bypass hose (from No.2 water bypass pipe) to throttle body
- Air hose to IAC valve
8. INSTALL THROTTLE BODY BRACKET

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)

9. INSTALL NO.2 VACUUM PIPE AND VSV ASSEMBLY

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)

10. CONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR
11. INSTALL EGR PIPE
(a) Temporarily install the union nut of the EGR pipe.
(b) Install a new gasket and the EGR pipe to the cylinder head with the 2 bolts.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)

(c) Tighten the union nut of the EGR pipe.

Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

12. INSTALL VSV FOR FUEL PRESSURE CONTROL
13. INSTALL INTAKE AIR CONNECTOR PIPE
14. CONNECT CONTROL CABLES TO THROTTLE BODY
15. FILL WITH ENGINE COOLANT
16. CHECK FOR FUEL LEAKS

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