LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2007 >> IS 250 AWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel (4GR-FSE) >> Fuel Injector, Intake Manifold >> Removal

Fuel Injector, Intake Manifold: Removal

  1. REMOVE COOL AIR INTAKE DUCT SEAL (See  REMOVAL  ) 
  2. REMOVE ENGINE ROOM SIDE COVER LH (See Step 2 in  REMOVAL  ) 
  3. REMOVE ENGINE ROOM SIDE COVER RH (See Step 3 in  REMOVAL  ) 
  4. REMOVE V-BANK COVER SUB-ASSEMBLY (See Step 4 in  REMOVAL  ) 
  5. REMOVE FRONT UPPER FENDER PROTECTOR LH (See Step 4 in  REMOVAL  ) 
  6. REMOVE FRONT UPPER FENDER PROTECTOR RH 

    HINT:

    Removal procedure of the RH side is the same as that of the LH side.

  7. REMOVE ROOF DRIP SIDE FINISH MOLDING LH (See  REMOVAL  ) 
  8. REMOVE ROOF DRIP SIDE FINISH MOLDING RH 

    HINT:

    Removal procedure of the RH side is the same as that of the LH side.

  9. REMOVE FRONT WIPER ARM HEAD CAP (See Step 8 in  REMOVAL  ) 
  10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See Step 9 in  REMOVAL  ) 
  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See Step 10 in  REMOVAL  ) 
  12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See Step 11 in  REMOVAL  ) 
  13. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See PRECAUTION  .

  14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  15. DRAIN ENGINE COOLANT (See Step 4 in  ON-VEHICLE INSPECTION  ) 
  16. DISCONNECT NO. 2 VENTILATION HOSE (See Step 5 in  REMOVAL  ) 
  17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See Step 6 in  REMOVAL  ) 
  18. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY (See Step 7 in  REMOVAL  ) 
  19. SEPARATE COLD START INJECTOR 
    1. Disconnect the cold start injector connector.
    2. Separate the 2 bolts and cold start injector.
    Fig 1: Removing Cold Start Injector
    G04044505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the vacuum hose from the intake air surge tank.
    2. Remove the bolt and disconnect the No. 1 vacuum switching valve assembly from the intake air surge tank.
      Fig 2: Disconnecting No. 1 Vacuum Switching Valve Assembly From Intake Air Surge Tank
      G04044506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the wire harness and hose from the surge tank.
      Fig 3: Disconnecting Wire Harness & Hose From Surge Tank
      G04044507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the ventilation hose from the intake air surge tank.
      Fig 4: Disconnecting Ventilation Hose From Intake Air Surge Tank
      G04044508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and water hose joint from the intake air surge tank.
      Fig 5: Removing Water Hose Joint From Intake Air Surge Tank
      G04044509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and disconnect the surge tank stay.
      Fig 6: Disconnecting Surge Tank Stay
      G04044510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.
    Fig 7: Removing Bolts & Nuts
    G04044511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INTAKE MANIFOLD 
    1. Disconnect the connector for the SCV.
    2. Disconnect the SCV position sensor connector.
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
    Fig 8: Removing Intake Manifold
    G04044512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT WATER HOSE JOINT 
    1. Remove the bolt and water hose joint.
    Fig 9: Removing Water Hose Joint
    G04044513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FUEL PRESSURE PULSATION DAMPER 
    1. Using SST, remove the fuel pressure pulsation damper from the fuel pump.
    Fig 10: Removing Fuel Pressure Pulsation Damper From Fuel Pump
    G04044514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE NO. 1 FUEL PIPE 
    1. Disconnect the No. 3 fuel hose from the No. 1 fuel pipe.
      Fig 11: Disconnecting No. 3 Fuel Hose From No. 1 Fuel Pipe
      G04044515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 fuel hoses.
    3. Remove the 2 bolts and No. 1 fuel pipe.
    Fig 12: Removing No. 1 Fuel Pipe
    G04044516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT NO. 2 FUEL PIPE (See Step 25 in  REMOVAL   ) 
  26. REMOVE FUEL PUMP ASSEMBLY (See Step 26 in  REMOVAL   ) 
  27. REMOVE NO. 2 FUEL PIPE 
    1. Remove the fuel pipe from the fuel delivery pipe.
      Fig 13: Removing No. 2 Fuel Pipe From Fuel Delivery Pipe
      G04044517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
    2. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.
  28. REMOVE NO. 3 FUEL PIPE 
    1. Remove the 4 bolts and fuel pipe from the fuel delivery pipe.
      Fig 14: Removing No. 3 Fuel Pipe
      G04044518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
    2. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.
  29. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the 3 wire harness clamps.
    2. Remove the 2 bolts and 2 nuts.
      Fig 15: Removing Wire Harness Clamps
      G04044519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the delivery pipe.
      Fig 16: Disconnecting Delivery Pipe
      G04044520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).
      • Be extremely careful not to touch or strike the tips of the injectors.
      • Pull and remove the fuel pipe in a straight line without tilting it.
    4. Disconnect the 3 connectors from the 3 injectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
  30. REMOVE NO. 1 FUEL DELIVERY PIPE 
    1. Disconnect the 2 wire harness clamps.
    2. Remove the 2 bolts and 2 nuts.
      Fig 17: Removing Wire Harness Clamps
      G04044521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the No. 1 fuel delivery pipe.
      Fig 18: Removing No. 1 Fuel Delivery Pipe
      G04044522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be extremely careful not to touch or strike the tips of the injectors.
      • Pull and remove the fuel pipe in a straight line without tilting it.
    4. Disconnect the 3 connectors from the 3 injectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
  31. REMOVE FUEL INJECTOR 
    1. Secure the delivery pipe in a vise between aluminum plates and pull out the injector in a straight line.
      Fig 19: Removing Fuel Injector
      G04044523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
      • For reinstallation, attach a tag or label to the injector shaft.
    2. Remove the nozzle holder clamps from the injectors.
    3. Remove the O-ring, backup rings and E-ring from the fuel injector.
  32. REMOVE FUEL INJECTOR SEAL 
    1. Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.
      Fig 20: Removing Fuel Injector Seal
      G04044524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Excessively pinching the injector seal may damage the groove of the injector.
      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.
    2. Remove the 2 injector seals from the injector.
scientia non olet · About LEMON Manuals