Toyota Camry

 XV30 (2002–2006) Service Manual

Fuel
Fuel injector assy (1MZ−FE/3MZ−FE)

COMPONENTS

REPLACEMENT

1. DISCHARGE FUEL SYSTEM PRESSURE

2. DRAIN ENGINE COOLANT

3. REMOVE FRONT SUSPENSION UPPER BRACE CENTER

a. Remove the 2 nuts and upper brace.

4. REMOVE V−BANK COVER SUB−ASSY

5. REMOVE AIR CLEANER CAP SUB−ASSY

1. Disconnect the MAF meter connector.
2. Disconnect the 4 vacuum hoses.
3. Disconnect the ventilation hose No. 2.
4. Remove the fuel vapor feed hose from the 2 hose clamps.
5. Loosen the 2 air cleaner cap bolts.
6. Loosen the air cleaner hose clamp bolt, and remove the air cleaner cap.
7. Remove the air cleaner filter element.

Remove air cleaner cap sub-assy

6. REMOVE EMISSION CONTROL VALVE SET (1MZ−FE ENGINE TYPE)

1. Disconnect the 3 VSV connectors.
2. Remove the wire harness clamp.

3. Disconnect the fuel vapor feed hose No. 1.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 3 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts, and then remove the emission control valve set.

7. REMOVE EMISSION CONTROL VALVE SET (3MZ−FE ENGINE TYPE)

1. Disconnect the 2 VSV connectors.
2. Remove the wire harness clamp.

3. Disconnect the fuel vapor feed hose No. 1.
4. Disconnect the fuel vapor feed hose No. 2.
5. Disconnect the 2 vacuum hoses.
6. Remove the clamp.
7. Remove the 2 nuts and the emission control valve set.

8. REMOVE INTAKE AIR SURGE TANK

1. Disconnect the throttle motor connector.
2. Disconnect the water bypass hose No. 3.
3. Disconnect the water bypass hose No. 2.
4. Disconnect the union to check valve hose.

e. Disconnect the ventilation hose.

f. Remove the 3 nuts and separate the pressure feed tube.

7. Remove the 2 bolts and engine hunger No. 1.
8. Remove the 2 bolts and surge tank stay No. 1.
9.  Remove the 2 bolts and surge tank stay No. 2.

10. Using a socket hexagon wrench 8, remove the 4 bolts.
11.  Remove the 2 nuts, emission control valve bracket and intake air surge tank.
12. Remove the gasket from the intake air surge tank.

9. SEPARATE FUEL PIPE SUB−ASSY No.1

1. Remove the bolt and disconnect the fuel pipe No. 1.
2. Remove the fuel pressure pulsation damper and 2 gaskets.
3. Remove the fuel pipe No. 2 union bolt and 2 gaskets.

Separate fuel pipe sub-assy No.1

10. REMOVE FUEL INJECTOR ASSY

a. Disconnect the 6 fuel injector connectors.

b. Remove the 4 bolts and 2 fuel delivery pipes together with the 6 fuel injectors.

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

c. Remove the 4 delivery pipe No. 1 spacers ( 1) and 6 insulators ( 2) from the intake manifold.

d. Pull out the fuel injector from the fuel delivery pipe.

11. INSTALL FUEL INJECTOR ASSY

1. Install a new grommet to each injector.
2. Apply a light coat of grease or gasoline to a new O−ring, and install it to each injector.

3. Apply a light coat of grease or gasoline on the place where the fuel delivery pipe contacts the O−ring.
4. Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.

NOTICE:

• Be careful not to twist the O−ring.

• After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O−ring.

5. Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
6. Place the 2 fuel delivery pipes and the 6 fuel injectors together on the intake manifold.

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

g. Temporarily install the 4 bolts which are used to attach the fuel delivery pipe to the intake manifold.

NOTICE: After installing the fuel injector, check that it turns smoothly.

If not, reinstall it with a new O−ring.

8. Tighten the 4 bolts.

   Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)

9. Connect the 6 fuel injector connectors.

12. INSTALL FUEL PIPE SUB−ASSY No.1

1. Install 2 new gaskets and the fuel pipe No. 2 union bolt.

   Torque: 33 N·m (337 kgf·cm, 24 ft·lbf)

2. Install 2 new gaskets and the fuel pressure pulsation damper.

   Torque: 33 N·m (337 kgf·cm, 24 ft·lbf)

3. Install the fuel pipe No. 1 Ωith the bolt.

   Torque: 20 N·m (204 kgf·cm, 14 ft·lbf)

13. INSTALL INTAKE AIR SURGE TANK

1. Install a new gasket to the intake air surge tank.
2. Install the intake air surge tank and emission control valve bracket with the 2 nuts.

   Torque: 28 N·m (286 kgf·cm, 21 ft·lbf)

3. Using a socket hexagon wrench 8, tighten the 4 bolts.

   Torque: 28 N·m (286 kgf·cm, 21 ft·lbf)

4. Install the surge tank stay No. 2 Ωith the 2 bolts.

   Torque: 20 N·m (204 kgf·cm, 14 ft·lbf)

5. Install the surge tank stay No. 1 Ωith the 2 bolts.

   Torque: 20 N·m (204 kgf·cm, 14 ft·lbf)

6. Install the engine hunger No. 1 Ωith the 2 bolts.

   Torque: 20 N·m (204 kgf·cm, 14 ft·lbf)

7. Install the pressure feed tube with the 3 nuts.

   Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

8. Connect the ventilation hose.
9. Connect the union to check valve hose.
10. Connect the water bypass hose No. 2.
11. Connect the water bypass hose No. 3.
12. Connect the throttle motor connector.

14. INSTALL EMISSION CONTROL VALVE SET (1MZ−FE ENGINE TYPE) Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

15. INSTALL EMISSION CONTROL VALVE SET (3MZ−FE ENGINE TYPE) Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

16. INSTALL AIR CLEANER CAP SUB−ASSY Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf)

17. CHECK CONNECTION OF VACUUM HOSE

18. ADD ENGINE COOLANT

19. CHECK FOR ENGINE COOLANT LEAKS

20. CHECK FOR FUEL LEAKS

21. INSTALL V−BANK COVER SUB−ASSY

22. INSTALL FRONT SUSPENSION UPPER BRACE CENTER

a. Install the upper brace with the 2 nuts.

Torque: 80 N·m (815 kgf·cm, 59 ft·lbf)

Fuel system (2AZ−FE)(From July, 2003)

Fuel injector assy (2AZ−FE)(From July, 2003)

Fuel pump assy (2AZ−FE)(From July, 2003)

Fuel tank assy (2AZ−FE)(From July, 2003)

Fuel system (1MZ−FE/3MZ−FE)

Fuel injector assy (1MZ−FE/3MZ−FE)

Fuel system (2AZ−FE)(From July, 2003)

Fuel pump assy (1MZ−FE/3MZ−FE)

Fuel tank assy (1MZ−FE/3MZ−FE)

Fuel system (2AZ−FE)(From July, 2003)

Fuel injector assy (2AZ−FE)(From July, 2003)