This procedure covers the removal and replacement of a single fuel injector on the 2.5L 2AR-FE engine, including relieving fuel system pressure and accessing the fuel rail.

Warnings

Tools required

Parts

• Fuel injector × 1 — Use OEM specification or verified aftermarket equivalent
• Fuel injector O-ring kit × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
4. Place absorbent pads and container under work area to catch fuel spillage
5. Have fire extinguisher nearby

Procedure

1. 1

   Relieve fuel system pressure
   Remove fuel pump relay (EFI MAIN relay) from engine bay fuse box. Attempt to start engine and let it run until it stalls. Crank engine for 3-5 additional seconds to ensure pressure is relieved. Turn ignition off.
2. 2

   Remove engine cover
   Remove the plastic engine cover by lifting upward on the front edge, then pulling forward to disengage the rear mounting grommets. Set aside.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect fuel supply line
   Locate the fuel feed line on the driver's side of the fuel rail. Press the fuel line disconnect tool into the quick-connect fitting while pulling the fuel line away from the rail. Catch any residual fuel with shop towels. Inspect the O-ring on the fuel rail connection and prepare new O-ring for installation.
4. 4

   Disconnect electrical connections
   Depress the lock tab on each fuel injector electrical connector and disconnect. If replacing injector #1 or #4, you may need to disconnect additional wiring harness clips for better access. Note the routing of the wiring harness for reassembly.
5. 5

   Remove fuel rail mounting bolts
   Remove the two 12mm fuel rail mounting bolts located at each end of the fuel rail assembly. Keep bolts organized for reinstallation.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
6. 6

   Remove fuel rail assembly
   Carefully pull the fuel rail assembly straight upward with even pressure to extract all four injectors from their bores simultaneously. The injectors are sealed with O-rings and may require moderate force. Rock the rail gently side-to-side if needed, but do not pry or bend the rail.
7. 7

   Remove target fuel injector
   With fuel rail removed, locate the retaining clip securing the faulty injector to the fuel rail. Use a small flathead screwdriver to pry the clip off, working it side-to-side. Once clip is removed, pull the injector straight out of the fuel rail. Note the orientation of the injector and O-ring positions.
8. 8

   Prepare new fuel injector
   Install new O-rings on the new fuel injector. Apply a light coat of clean gasoline to both O-rings (upper rail seal and lower manifold seal) to ease installation. Ensure O-rings are seated properly in their grooves without twisting or pinching.
9. 9

   Install new fuel injector to rail
   Insert the new injector into the fuel rail bore in the same orientation as the original. Push firmly until fully seated. Install the retaining clip by pressing it into position until it clicks, securing the injector to the rail. Verify the clip is fully engaged on both sides.
10. 10

    Reinstall fuel rail assembly
    Clean the injector bores in the intake manifold with a lint-free cloth. Carefully align all four injectors with their respective bores and press the fuel rail assembly straight down with even pressure until all injectors are fully seated. Ensure the rail mounting holes align with the threaded bosses on the intake manifold.
11. 11

    Install fuel rail bolts
    Thread both fuel rail mounting bolts by hand to ensure proper thread engagement. Torque both bolts evenly in a cross-pattern to specification using a calibrated torque wrench.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
12. 12

    Reconnect fuel supply line
    Install the new O-ring on the fuel rail quick-connect fitting. Push the fuel supply line firmly onto the fuel rail connection until you hear and feel a positive click. Gently tug on the line to verify it is securely locked.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
13. 13

    Reconnect electrical connections
    Reconnect all fuel injector electrical connectors, ensuring each clicks securely into place. Reinstall any wiring harness clips that were removed. Verify connectors are fully seated and locked.
14. 14

    Check for leaks and test
    Reinstall the fuel pump relay. Reconnect the negative battery terminal. Turn ignition to ON position (do not start) for 2 seconds, then OFF. Repeat this cycle 3 times to prime the fuel system. Carefully inspect all fuel connections for leaks. If no leaks are present, start the engine and verify smooth operation.

Reassembly

1. Reinstall engine cover by aligning rear grommets first, then pressing down on front mounting points until secure
2. Clear all tools and materials from engine bay
3. Properly dispose of old fuel injector and contaminated shop towels according to local regulations

Verification

• Start engine and allow to idle for 2-3 minutes, listening for smooth operation without misfires
• Check fuel rail and injector connections carefully for any signs of fuel leakage
• Verify no fuel odor in engine bay or cabin
• Use scan tool to verify no fuel system or misfire diagnostic trouble codes are present
• Test drive vehicle to confirm normal acceleration and no hesitation or rough running under load

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