Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000YQRU
Model Year Start: 2017 Model: Sienna Prod Date Range: [08/2016 -           ]
Title: 2GR-FKS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2017 - 2020 MY Sienna [08/2016 -        ]

REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

Click here 2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (FUEL): FUEL PUMP(for High Pressure): REMOVAL

2. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

CAUTION:

To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.

(a) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 2 fuel pipe sub-assembly.

(b) Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.

3. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.

(b) Disengage the 2 clamps to remove the wire harness clamp bracket.

4. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

(a) Disconnect the fuel pressure sensor connector.

(b) Remove the bolt.

(c) Disengage the clamp to disconnect the No. 7 engine wire from the fuel delivery pipe with sensor assembly LH.

(d) Remove the 2 bolts, 2 nuts and fuel delivery pipe with sensor assembly LH with the fuel injector assemblies.

Bolt

Nut

NOTICE:

  • Make sure not to touch or strike the tips of the fuel injector assemblies.
  • Pull and remove the fuel delivery pipe with sensor assembly LH in a straight line without tilting it.

(e) Disconnect the 3 fuel injector assembly connectors.

5. REMOVE FUEL DELIVERY PIPE RH

(a) Remove the bolt.

(b) Disengage the clamp to disconnect the No. 6 engine wire from the fuel delivery pipe RH.

(c) Remove the 2 bolts, 2 nuts and fuel delivery pipe RH with the fuel injector assemblies.

Bolt

Nut

NOTICE:

  • Make sure not to touch or strike the tips of the fuel injector assemblies.
  • Pull and remove the fuel delivery pipe RH in a straight line without tilting it.

(d) Disconnect the 3 fuel injector assembly connectors.

6. REMOVE FUEL INJECTOR ASSEMBLY

(a) Secure the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH in a vise between aluminum plates and pull out the 6 fuel injector assemblies.

NOTICE:

  • Pull and remove each fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH O-ring.
  • After removing the fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH side.
  • Attach a tag or label with the corresponding cylinder number to each fuel injector assembly so that they can be installed to their original locations.

(b) Remove the nozzle holder clamp from each fuel injector assembly.

(c) Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each fuel injector assembly.

NOTICE:

Do not damage the area that contacts the O-ring.

(d) Remove the O-ring and No. 1 fuel injector back-up ring from each fuel injector assembly.

(e) Remove the C-ring and injector vibration insulator from each fuel injector assembly.

7. REMOVE FUEL INJECTOR SEAL

(a) Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

NOTICE:

  • Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.
  • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.

(b) Remove the fuel injector seal from each fuel injector assembly.