G16E-GTS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2023 MY GR Corolla [09/2022

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM1000000025V97
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [09/2022 - 11/2022]
Title: G16E-GTS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2023 MY GR Corolla [09/2022 - 11/2022]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during direct fuel injector assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of direct fuel injector assembly Replacement of fuel pump assembly Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly	Inspection after repair	Poor idle, etc. Engine start function, etc.

CAUTION:

Never perform work on fuel system components near any possible ignition sources.
Vaporized fuel could ignite, resulting in a serious accident.

Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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HINT:

When the cable is disconnected / reconnected to the battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System (for TMC Made)	Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Power Door Lock Control System Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. REMOVE DECK BOARD ASSEMBLY

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4. REMOVE SPARE WHEEL CUSHION

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5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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6. REMOVE INTAKE MANIFOLD

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7. REMOVE FUEL PUMP ASSEMBLY

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8. SEPARATE NO. 2 WATER BY-PASS PIPE

(a) Remove the nut and bolt to separate the No. 2 water by-pass pipe from the cylinder block sub-assembly.

9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

NOTICE:

When replacing the fuel delivery pipe sub-assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

(a) Remove the 4 bolts and fuel delivery pipe sub-assembly with the 3 direct fuel injector assemblies from the cylinder head sub-assembly.

NOTICE:

If fuel intrudes into the combustion chamber, there may be adverse affects to the engine main body.
Make sure not to touch or strike the tips of the direct fuel injector assemblies.
Pull and remove the fuel delivery pipe sub-assembly in a straight line without tilting it.

10. REMOVE NO. 6 ENGINE WIRE

(a) Disengage the 2 clamps.

(b) Disconnect the 3 direct fuel injector assembly connectors and remove the No. 6 engine wire from the fuel delivery pipe sub-assembly.

11. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

(a) Secure the fuel delivery pipe sub-assembly in a vise between aluminum plates and pull out the 3 direct fuel injector assemblies.

NOTICE:

Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe sub-assembly O-ring.
After removing the direct 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 sub-assembly side.
Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.
Cover the tip of each direct fuel injector assembly to prevent it from being damaged.

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

(e) Remove the C-ring from each direct fuel injector assembly.

(f) Remove the injector vibration insulator from each direct fuel injector assembly.

12. 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 direct fuel injector assembly.
If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.

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