G16E-GTS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL; 2023 - 2025 MY GR Corolla [11/2022

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM1000000028INQ
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [11/2022 - ]
Title: G16E-GTS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL; 2023 - 2025 MY GR Corolla [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 port 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 port fuel injector 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	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. DRAIN ENGINE COOLANT

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7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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8. SEPARATE ENGINE WIRE

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9. REMOVE FUEL PIPE CLAMP

(a) Remove the fuel pipe clamp from the fuel tube connector.

10. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

(a) Disconnect the No. 2 fuel tube sub-assembly from the fuel delivery pipe.

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11. REMOVE NO. 4 WATER BY-PASS PIPE

(a) Remove the 3 bolts and No. 4 water by-pass pipe from the cylinder head sub-assembly.

12. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

(a) Remove the oil level gauge sub-assembly.

13. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the bolt and oil level gauge guide from the cylinder head sub-assembly.

(b) Remove the O-ring from oil level gauge guide.

14. REMOVE FUEL DELIVERY GUARD

(a) Disengage the wire harness clamp.

(b) Remove the 2 bolts, 2 nuts and fuel delivery guard from the cylinder head sub-assembly and cylinder head cover sub-assembly.

15. REMOVE FUEL DELIVERY PIPE

(a) Disconnect the No. 5 engine wire connector.

(b) Remove the 2 bolts and fuel delivery pipe with the 3 port 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.
Be careful not to drop the port fuel injector assemblies when removing the fuel delivery pipe.

16. REMOVE FUEL DELIVERY SPACER

(a) Remove the 2 fuel delivery spacers from the cylinder head sub-assembly.

17. REMOVE INJECTOR VIBRATION INSULATOR

(a) Remove the 3 injector vibration insulators from the cylinder head sub-assembly.

18. REMOVE NO. 5 ENGINE WIRE

(a) Disconnect the 3 port fuel injector assembly connectors and fuel pressure sensor connector.

(b) Disengage the 2 clamps to remove the No. 5 engine wire from the fuel delivery pipe.

19. REMOVE PORT FUEL INJECTOR ASSEMBLY

(a) Pull the 3 port fuel injector assemblies out of the fuel delivery pipe.

(b) Remove the O-ring from each port fuel injector assembly.

(c) Attach a tag or label with the corresponding cylinder number to each port fuel injector assembly so that they can be installed to their original locations.

NOTICE:

Cover the port fuel injector assemblies with plastic bags to prevent damage and contamination.