Toyota Avalon (XX50): Fuel Injector(for Direct Injection)

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / 2gr-fks Fuel / Fuel Injector(for Direct Injection)

Components

COMPONENTS

ILLUSTRATION

*1	FUEL DELIVERY PIPE RH	*2	FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH
*3	FUEL INJECTOR ASSEMBLY	*4	FUEL INJECTOR SEAL
*5	NO. 2 FUEL PIPE SUB-ASSEMBLY	*6	WIRE HARNESS CLAMP BRACKET
*7	NO. 3 FUEL INJECTOR BACK-UP RING	*8	O-RING
*9	NO. 1 FUEL INJECTOR BACK-UP RING	*10	NOZZLE HOLDER CLAMP
*11	INJECTOR VIBRATION INSULATOR	*12	C-RING
*13	NO. 6 ENGINE WIRE	*14	NO. 7 ENGINE WIRE
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque
*	For use with a union nut wrench	●	Non-reusable part

Inspection

INSPECTION

PROCEDURE

1. INSPECT FUEL INJECTOR ASSEMBLY

NOTICE:

This inspection is for checking the fuel injector assembly for an open or short. Because the fuel injector assembly of this vehicle is a high-pressure type, fuel injection volume cannot be checked.

(a) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
1 - 2	20°C (68°F)	1.74 to 2.04 Ω

If the result is not as specified, replace the fuel injector assembly.

*a	Component without harness connected (Fuel Injector Assembly)

Installation

INSTALLATION

PROCEDURE

1. INSTALL FUEL INJECTOR SEAL

(a) Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector assembly and its grooves.

NOTICE:

Do not clean the tip of the fuel injector assembly.
Do not use a wire brush to clean 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.

*a	Area to be Cleaned

(b) Apply engine oil to the fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the fuel injector assembly with the chamfer facing the tip of the fuel injector assembly as shown in the illustration.

SST: 09260-39021

09261-03020

*a	SST (Guide)
*b	Chamfer

SST: 09260-39021

09261-03011

NOTICE:

Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal.

*1	Fuel Injector Seal
*a	SST (Holder)
*b	Correct
*c	Incorrect

(d) Install SST (holder) with the fuel injector seal to the tip of the fuel injector assembly. Slide the fuel injector seal downward into the fuel injector assembly groove with your fingers as shown in the illustration.

SST: 09260-39021

09261-03011

09261-03020

HINT:

Check that the fuel injector seal is seated in the fuel injector assembly groove as shown in the illustration.

*a	SST (Holder)
*b	SST (Guide)

(e) Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the fuel injector assembly groove.

SST: 09260-39021

09261-03020

NOTICE:

Make sure the fuel injector seal is not pinched between SST (guide) and the edge of the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

HINT:

Set SST (guide) so that its bottom surface is flush with the fuel injector seal.
If it is difficult to slide SST (guide) upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.

*a	SST (Guide)

(f) After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the fuel injector assembly groove.

NOTICE:

If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

HINT:

Use the same procedure to install the other fuel injector seals.

*a	Normal
*b	Protruding
*c	Deformed
*d	Correct
*e	Incorrect

2. INSTALL FUEL INJECTOR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing a fuel injector assembly.

Click here

(a) Install a new injector vibration insulator and a new C-ring to each fuel injector assembly.

NOTICE:

Install the taper of the injector vibration insulator by aligning it with the taper of the fuel injector assembly.
Check that the C-ring is securely seated in the groove of the fuel injector assembly.

*1	Fuel Injector Assembly
*2	C-ring
*3	Injector Vibration Insulator
*a	Taper

(b) Install a new O-ring and a new No. 1 fuel injector back-up ring to each fuel injector assembly as shown in the illustration.

*1	No. 1 Fuel Injector Back-up Ring	*2	O-ring
*a	No. 1 Fuel Injector Back-up Ring Opening	*b	Overlapped
*c	Stretched	*d	Correct
*e	Incorrect	-	-

NOTICE:

Check that there is no foreign matter or damage on the O-ring groove of the fuel injector assembly.
Make sure that the No. 1 fuel injector back-up ring is installed in the correct orientation.
Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.
Check that the opening of the No. 1 fuel injector back-up ring is not overlapped or stretched as shown in the illustration.
After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

(c) With the notch of a new No. 3 fuel injector back-up ring facing downward, install the No. 3 fuel injector back-up ring to each fuel injector assembly as shown in the illustration.

NOTICE:

Make sure that the No. 3 fuel injector back-up ring is installed in the correct orientation.
After installing the No. 3 fuel injector back-up ring, make sure there is no damage or foreign matter.

*1	Fuel Injector Assembly
*2	No. 3 Fuel Injector Back-up Ring
*a	Notch

(d) Install the nozzle holder clamp to each fuel injector assembly.

(e) Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, and insert the fuel injector assembly.

*a	Protrusion
*b	Positioning Hole
	No Gap

NOTICE:

Make sure that there is no foreign matter or damage inside the fuel injector assembly installation holes (fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH).
Do not allow gasoline to get on the O-rings or inside the installation holes.
If it is difficult to insert the fuel injector assembly, apply new engine oil to the chamfer of the fuel injector assembly installation hole of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH. Be careful not to allow the fuel injector assembly to fall out of the fuel delivery pipe with sensor assembly LH or fuel delivery pipe RH.
Do not tilt the fuel injector assembly when inserting it into the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.
Check that there is no gap between the fuel delivery pipe with sensor assembly LH, fuel delivery pipe RH and the nozzle holder clamp.
*a

QR Code

*b

Flow Classification Number

Make sure the 3 fuel injector assemblies of each bank all have the same flow classification number and that the flow classification number is 1, 2 or 3 (it is acceptable for each bank to have a different flow classification number).

3. INSTALL FUEL DELIVERY PIPE RH

(a) Connect the 3 fuel injector assembly connectors.

(b) Apply lubricant to the fuel injector assembly installation holes of the cylinder head sub-assembly.

(c) Temporarily install the fuel delivery pipe RH to the cylinder head sub-assembly so that the stud bolts protrude enough to install the nuts.

NOTICE:

If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the cylinder head sub-assembly.
When installing the fuel delivery pipe RH, push it in evenly without tilting it.

*a	Protruding enough to install nut

(d) Install the fuel delivery pipe RH by uniformly tightening the 2 bolts and 2 nuts in the order shown in the illustration.

	Bolt
	Nut

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(e) Engage the clamp to connect the No. 6 engine wire to the fuel delivery pipe RH.

(f) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

4. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

(a) Connect the 3 fuel injector assembly connectors.

(b) Apply lubricant to the fuel injector assembly installation holes of the cylinder head LH.

(c) Temporarily install the fuel delivery pipe with sensor assembly LH to the cylinder head LH so that the stud bolts protrude enough to install the nuts.

NOTICE:

If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the cylinder head LH.
When installing the fuel delivery pipe with sensor assembly LH, push it in evenly without tilting it.

*a	Protruding enough to install nut

(d) Install the fuel delivery pipe with sensor assembly LH by uniformly tightening the 2 bolts and 2 nuts in the order shown in the illustration.

	Bolt
	Nut

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(e) Engage the clamp to connect the No. 7 engine wire to the fuel delivery pipe with sensor assembly LH.

(f) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(g) Connect the fuel pressure sensor connector.

5. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Engage the 2 clamps to install the wire harness clamp bracket.

(b) Connect the No. 6 engine wire connector and No. 7 engine wire connector.

6. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Temporarily install the No. 2 fuel pipe sub-assembly to the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH and tighten the 2 union nuts by hand.

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

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

If the 2 union nuts cannot be fastened, loosen the nuts of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH, and then fasten both union nuts.
Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
This torque value is effective when the union nut wrench is parallel to the torque wrench.
Install the union nut wrench parallel with the torque wrench.

*a	17 mm Union Nut Wrench
*b	Torque Wrench Fulcrum Length

7. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

Click here

8. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing a fuel injector assembly.

Click here

Removal

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 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
*: When performing learning using the Techstream. Click here
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Departure Alert System (w/ Steering Control)
		Pre-collision System
		Intelligent Clearance Sonar System*
		Lighting System (for Gasoline Model with Cornering Light)
	Memorize steering angle neutral point	Parking Assist Monitor System
	Memorize steering angle neutral point	Panoramic View Monitor System
Replacement of fuel injector assembly (for Port Injection) Replacement of fuel injector assembly (for Direct Injection) 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.
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.

PROCEDURE

1. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

Click here

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.

(d) Remove the 2 bolts, 2 nuts and fuel delivery pipe with sensor assembly LH with the 3 fuel injector assemblies from the cylinder head LH.

	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 3 fuel injector assemblies from the cylinder head sub-assembly.

	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.

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.

Fuel Filter

Fuel Injector(for Port Injection)

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*a	QR Code
*b	Flow Classification Number