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Home >> Lexus >> 2007 >> IS 350 >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel (2GR-FSE) >> Fuel Injector (For Direct Injection), Intake Manifold >> Removal

Fuel Injector (For Direct Injection), Intake Manifold: Removal

  1. REMOVE COOL AIR INTAKE DUCT SEAL (See  REMOVAL  ) 
  2. REMOVE ENGINE ROOM SIDE COVER LH (See  REMOVAL  ) 
  3. REMOVE ENGINE ROOM SIDE COVER RH (See  REMOVAL  ) 
  4. REMOVE V-BANK COVER SUB-ASSEMBLY (See  REMOVAL  ) 
  5. REMOVE FRONT UPPER FENDER PROTECTOR LH (See  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 MOULDING LH (See  REMOVAL  ) 
  8. REMOVE ROOF DRIP SIDE FINISH MOULDING 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  REMOVAL  ) 
  10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See  REMOVAL  ) 
  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See  INSTALLATION  ) 
  12. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See  REMOVAL  ) 
  13. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See FUEL SYSTEM  .

  14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  15. DRAIN ENGINE COOLANT (See  COOLANT  ) 
  16. DISCONNECT NO. 2 VENTILATION HOSE (See  REMOVAL  ) 
  17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See  REMOVAL  ) 
  18. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY (See  REMOVAL  ) 
  19. REMOVE INTAKE AIR SURGE TANK (See  REMOVAL   ) 
  20. REMOVE INTAKE MANIFOLD 
    1. Disconnect the fuel tube from the delivery pipe subassembly.
      Fig 1: Disconnecting Fuel Tube From Delivery Pipe Subassembly
      G04056424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matte contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
      • Do not use any tools to separate the pipe and connector.
      • Do not forcefully bend or twist the nylon tube.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
    2. Disconnect the 4 connectors.
      Fig 2: Identifying Connectors
      G04056425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
      Fig 3: Identifying Bolts, Nuts, Intake Manifold And Gasket
      G04056426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE WATER HOSE JOINT 
    1. Remove the bolt and disconnect the water hose joint.
      Fig 4: Identifying Water Hose Joint
      G04056427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL PRESSURE PULSATION DAMPER 
    1. Using SST, remove the fuel pressure pulsation damper from the fuel pump.
      Fig 5: Removing Fuel Pressure Pulsation Damper Using SST
      G04056428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09612-24014 (09617-24011) 

  23. REMOVE NO. 1 FUEL PIPE 
    1. Disconnect the No. 3 fuel hose from the No. 1 fuel pipe.
      Fig 6: Identifying No.1 Fuel Pipe
      G04056429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 fuel hoses.
    3. Remove the 2 bolts and No. 1 fuel pipe.
      Fig 7: Identifying Fuel Hoses
      G04056430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT NO. 2 FUEL PIPE (See  REMOVAL   ) 
  25. REMOVE FUEL PUMP ASSEMBLY (See  REMOVAL   ) 
  26. REMOVE NO. 2 FUEL PIPE 
    1. Remove the fuel pipe from the fuel delivery pipe.
      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.
      Fig 8: Removing Fuel Pipe From Fuel Delivery Pipe
      G04056431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 3 FUEL PIPE 
    1. Remove the 4 bolts and fuel pipe from the fuel delivery pipe.
      Fig 9: Removing Bolts From Fuel Pipe
      G04056432Courtesy 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 to the No. 3 fuel pipe.
  28. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the 3 wire harness clamps.
      Fig 10: Identifying Wire Harness Clamps
      G04056433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 11: Identifying Bolts And Nuts
      G04056434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the No. 2 fuel delivery pipe.
      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 injector connectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
      Fig 12: Identifying Injector Connectors
      G04056435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 FUEL DELIVERY PIPE 
    1. Disconnect the 2 wire harness clamps and fuel pressure sensor connector.
      Fig 13: Identifying Wire Harness Clamps And Fuel Pressure Sensor Connector
      G04056436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 14: Identifying Bolts And Nuts
      G04056437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the No. 1 fuel delivery pipe.
      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 injector connectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
      Fig 15: Identifying Injector Connectors
      G04056438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FUEL INJECTOR ASSEMBLY 
    1. Secure the delivery pipe in a vise between aluminum plates and pull out the injector in a straight line.
      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.
      Fig 16: Identifying Fuel Injector Assembly
      G04056439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. 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 17: Identifying Fuel Injector Seal
      G04056440Courtesy 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.
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