Changed injectors and fuel filter 2003 2.7 with 222,000 miles

I had the P0302 code pop up about 2 weeks ago. This is a cylinder 2 misfire. Swapped the coil pack after checking the plugs. I swapped 1 and 2 coil pack. Reset the check engine light. Ran Techron fuel adder through the tank. Truck ran fine for a while then would random misfire after warm start up and trip flashing CEL. Did the troubleshooting for about a week and narrowed it down to injector.

Ordered refurbished Denso OEM injectors from Motor West Sports in Cali. I also ordered the fuel filter from Toyota. I figured 222,000 miles on the filter and injectors its probably time for some maintenance. This is how it went:

1. Disconnect negative battery terminal and round up necessary tools and courage.
2. Disconnect air intake hoses by loosening clamps and removing the two nuts under the air box. 10mm, 12mm for the bolts.
3. Remove throttle cables from throttle body by removing the two screws that hold the bracket to throttle body.
4. Remove IAC connector and hoses from throttle body. There are two coolant hoses under throttle body you will need to carefully remove. Pay attention to what you remove so everything goes back on properly. Speed kills!
5. Remove 4 bolts holding throttle body on to intake plenum. This would be a good time to clean the throttle body. If you do this DON'T get anything into the passages of the IAC as you will screw up the idle. That is another story and write up.
6. You will want to replace the gasket for the throttle body. Its paper.
7. Put a cloth over intake plenum as dirt is bad.
8. Remove all electrical connections CAREFULLY from the injectors.
9. Remove wiring harness from the back of valve cover and the middle of valve cover. The one in the back need to depress clip and lift.
10. Move harness to the left side and clamp out of the way. Be careful not to force or damage anything.
11. You will clearly see fuel rail with 4 injectors under.
12. Above drivers side wheel well locate the fuel line from tank. There is a connection there that you will need to remove with a 14mm flare wrench. Place a container under this connection to collect some fuel that will leak out. (This step is not necessary unless you are replacing fuel filter but highly recommended)
13. Find the fuel line connection to the fuel rail at the rear of the rail. This is a 17mm bolt and it is on tight for good reason. Use a 6 sided socket with extension. Remove nut and collect 2 critical washers that sandwich the line. (recommend new washers from Toyota)
14. Remove rubber hose at front connection fuel rail.
15. Remove two bolts holding fuel rail to motor.
16. Carefully lift up on fuel rail and remove rail and injectors from motor. BE CAREFUL NOT TO DROP ANYTHING IN THE HOLES< INCLUDING DIRT!
17. Inspect injector passages at motor and carefully vacuum out the area with high suction vacuum. DON'T GET ANY DEBRIS IN THE PASSAGES! PATIENCE! AREA MUST BE WELL VENTILATED and vacuum grounded. DON'T SMOKE!
18. If the small o-rings didn't come out when you removed injectors you will need to take needle nose to take them out after you clean the area good. This is a small o-ring pictured on the part that goes into the motor.
19. Take q-tips after the area is super clean and dip in fuel or thin oil. Swab each injector seat at motor to make sure the area is SUPER CLEAN, no exceptions. You will need to have patience when doing this. You may have to pass over each whole 4-5 times. When that is done do it again with q-tip in fuel to make sure its clean.
20. Take the new injectors and swab both seals at engine and rail with fuel one at time and install at the engine.
21. Install fuel rail to top of injectors.
22. Make sure to spin injector back and forth slightly before bolting rail down. Electrical connection needs to be correct direction.
23. Move to the fuel filter which is directly under intake plenum and bolted to the motor. (USE GENUINE TOYOTA FILTER HERE)
24. You will need to access both 12mm bolts on top and bottom of filter from the wheel well.
25. Remove filter with the lines attached as they have already been disconnected from fuel rail and location at wheel well.
26. Place filter on bench and clamp.
27. Disconnect line to filter and attach lines to filter with new washers. Torque it down to correct settings. (NO LEAKS YOU HAVE BEEN WARNED AND ARE RESPONSIBLE FOR MOVING TOO QUICK AND NOT PAYING ATTENTION. SPEED KILLS.)
28. Put everything back together just as you removed and make sure you double check everything.

TIPS: Keep the engine bay clean. Make sure you clean the motor as thorough as you can before doing this. Nothing worse than working on a dirty engine.

Time: 4 hours and 1.5 for the filter change.

Enjoy!

 

Nice work. Did this correct that issue you are/were having?

 

Nice. Think I might replace the v6 and get the old ones cleaned and tested.

 

Yes, as of now. Its amazing the difference in idle and smooth throttle response. I guess its to be expected after running with them for 222,000 miles. The injectors that came out don't look to bad. I will keep those and send them off to be rebuilt.

 

Sincere thanks for the write up.

Motor West Performance supplied the injectors.

https://motorwestperformance.com/