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

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
  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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