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Home >> Lexus >> 2006 >> GS 300 RWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel (3GR-FSE) >> Fuel Injector >> Removal

Fuel Injector: Removal

CAUTION: Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.
  1. DISCHARGE FUEL SYSTEM PRESSURE 
    CAUTION:
    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
    • Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
    1. Disconnect the cable from the negative (-) battery terminal.
      CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
    2. Disconnect the fuel pump connector.
    3. Connect the cable to the negative (-) battery terminal.
    4. Start the engine. After the engine has stopped on its own, turn the engine switch off.

      HINT:

      DTC P0171/P0172 (system too lean) may be set.

    5. Crank the engine again, then check that the engine does not start.
    6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
    7. Connect the fuel pump connector.
      Fig 1: Identifying Fuel Pump Connector
      G04018598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  3. REMOVE COOL AIR INTAKE DUCT SEAL (See  ON-VEHICLE INSPECTION  ) 
  4. REMOVE ENGINE UNDER COVER (See  ON-VEHICLE INSPECTION  ) 
  5. DRAIN ENGINE COOLANT (See  ON-VEHICLE INSPECTION  ) 
  6. REMOVE ENGINE ROOM SIDE COVER RH (See  ON-VEHICLE INSPECTION  ) 
  7. REMOVE V-BANK COVER (See  ON-VEHICLE INSPECTION  ) 
  8. DISCONNECT NO. 2 VENTILATION HOSE (See  ON-VEHICLE INSPECTION  ) 
  9. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See  ON-VEHICLE INSPECTION  ) 
  10. DISCONNECT COLD START INJECTOR (See  REMOVAL   ) 
  11. DISCONNECT WATER BYPASS HOSE (See  ON-VEHICLE INSPECTION  ) 
  12. DISCONNECT HEATER WATER INLET HOSE 
    1. Disconnect the hose from the water hose joint.
      Fig 2: Identifying Hose From Water Hose Joint
      G04018599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT HEATER WATER OUTLET HOSE 
    1. Disconnect the hose from the pipe.
      Fig 3: Identifying Hose From Pipe
      G04018600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE ENGINE REAR COVER 
    1. Remove the 3 clips and engine rear cover.
      Fig 4: Identifying Clips And Engine Rear Cover
      G04018601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disconnect the hose from the surge tank.
      Fig 5: Identifying Hose From Surge Tank
      G04018602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT VENTILATION HOSE 
    1. Disconnect the ventilation hose from the ventilation valve.
      Fig 6: Identifying Ventilation Hose From Ventilation Valve
      G04018603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT FUEL MAIN TUBE 
    1. Remove the fuel pipe clamp.
      Fig 7: Identifying Fuel Pipe Clamp
      G04018604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch and pull the fuel tube's connector to disconnect it from the fuel main pipe.
      Fig 8: Pulling Fuel Tube'S Connector
      G04018605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for foreign matter in the fuel tube around the fuel tube's connector. Clean it if necessary. Foreign matter can affect the O-ring's ability to seal the connector and fuel main pipe.
      • Do not use any tools to separate the connector and pipe.
      • Do not forcefully bend or twist the hose.
      • Keep the connector and pipe free from foreign matter.
      • If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
      • Put the connector in a plastic bag to prevent damage and contamination.
        • Fig 9: Covering With Plastic Bag
        G04018606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE INTAKE AIR SURGE TANK 
    Fig 10: Identifying Intake Air Surge Tank
    G04018607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the throttle motor connector.
    2. Disconnect the IACV connector.
    3. Disconnect the wire harness clamp from the surge tank.
    4. Remove the 2 bolts and intake manifold stay.
    5. Disconnect the 2 wire harness clamps from the surge tank stays.
    6. Remove the 4 bolts and 2 surge tank stays.
    7. Remove the bolt and disconnect the water hose joint.
    8. Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.

      HINT:

      Cover the intake manifold port to prevent foreign matter from entering it.

      Fig 11: Covering Intake Manifold Port
      G04018608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INTAKE MANIFOLD 
    1. Disconnect the DC motor connector for the SCV.
    2. Disconnect the SCV position sensor connector.
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.

      HINT:

      Cover the cylinder head intake port to prevent foreign matter from entering it.

      Fig 12: Identifying Bolts And Nuts, Intake Manifold And Gasket
      G04018609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FUEL PRESSURE PULSATION DAMPER 
    1. Remove the fuel pressure pulsation damper from the fuel pump.
      Fig 13: Identifying Fuel Pressure Pulsation Damper From Fuel Pump
      G04018610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 1 FUEL PIPE
    1. Disconnect the fuel pipe hose.
    2. Remove the 2 bolts and fuel pipe.
  22. DISCONNECT NO. 2 FUEL PIPE (see   22  ) 
  23. REMOVE HIGH PRESSURE SIDE FUEL PUMP (see  REMOVAL   ) 
  24. REMOVE NO. 2 FUEL PIPE 
    1. Remove the fuel pipe from the fuel delivery pipe.
      Fig 14: Identifying Fuel Pipe From Fuel Delivery Pipe
      G04018611Courtesy 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.
  25. REMOVE NO. 3 FUEL PIPE
    1. Remove the bolt and 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.
      Fig 15: Identifying Bolt And Fuel Pipe From Fuel Delivery Pipe
      G04018612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 FUEL DELIVERY PIPE
    1. Disconnect the 3 wire harness clamps.
    2. Remove the 2 bolts and 2 nuts.
      Fig 16: Identifying Bolts And Nuts
      G04018613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the 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 connectors from the 3 injectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
      Fig 17: Identifying Delivery Pipe
      G04018614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 1 FUEL DELIVERY PIPE
    1. Disconnect the 2 wire harness clamps.
    2. Remove the 2 bolts and 2 nuts.
      Fig 18: Identifying Bolts And Nuts
      G04018615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the No. 2 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 connectors from the 3 injectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
      Fig 19: Identifying Connectors From Injectors
      G04018616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FUEL INJECTOR 
    1. Remove the injectors from the delivery pipe.
      NOTE: Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
    2. Remove the nozzle holder clamp from the injector.
    3. Remove the E-ring, O-ring, No. 1 backup ring, No. 2 backup ring and No. 3 backup ring from the injector.
  29. 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.
    NOTE:
    • Excessively pinching the injector seal may damage the groove of the injector.
    • Be extremely careful not to touch or strike the tips of the injectors.
      Fig 20: Striking Tips Of Injectors
      G04018617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • If an injector is dropped, replace it with a new one.
  2. Remove the 2 injector seals from the injector.
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