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Home >> Lexus >> 2007 >> GS 350 RWD >> 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. PRECAUTION (See  REMOVAL  ) 
  2. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  3. 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.
  4. REMOVE COOL AIR INTAKE DUCT SEAL (See  REMOVAL  ) 
  5. REMOVE ENGINE ROOM SIDE COVER LH (See  REMOVAL  ) 
  6. REMOVE ENGINE ROOM SIDE COVER RH (See  REMOVAL  ) 
  7. REMOVE V-BANK COVER SUB-ASSEMBLY (See  REMOVAL  ) 
  8. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH (See  REMOVAL  ) 
  9. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH (See  REMOVAL  ) 
  10. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See  REMOVAL  ) 
  11. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See  REMOVAL  ) 
  12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See  REMOVAL  ) 
  13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See  REMOVAL  ) 
  14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See  REMOVAL  ) 
  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 BODY WITH MOTOR ASSEMBLY (See  REMOVAL  ) 
  19. REMOVE INTAKE AIR SURGE TANK (See  REMOVAL  ) 
  20. REMOVE INTAKE MANIFOLD 
    1. Disconnect the fuel tube from the delivery pipe sub-assembly.
      NOTE:
      • Check for any dirt and foreign matter 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.
      Fig 1: Pulling Fuel Tube Connector
      G05286903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 connectors.
      Fig 2: Locating Connectors
      G05286934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
    Fig 3: Locating Intake Manifold Gasket With Nuts
    G05286935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT WATER HOSE JOINT 
    1. Remove the bolt and disconnect the water hose joint.
      Fig 4: Identifying Water Hose Joint
      G05286936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL PRESSURE PULSATION DAMPER (See  REMOVAL  ) 
  23. REMOVE NO. 1 FUEL PIPE 
    1. Disconnect the No. 3 fuel hose from the No. 1 fuel pipe.
      Fig 5: Locating No 3 Fuel Hose And Clamp
      G05286937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 fuel hoses.
      Fig 6: Locating Fuel Hoses
      G05286938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and No. 1 fuel pipe.
  24. DISCONNECT NO. 2 FUEL PIPE (See  INSTALLATION  ) 
  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 7: Identifying No.2 Fuel Pipe
    G05286939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 3 FUEL PIPE 
    1. Remove the 4 bolts 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.
    2. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.
    Fig 8: Locating Bolts On Fuel Pipe
    G05286940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the 3 wire harness clamps.
      Fig 9: Locating Wire Harness Clamps
      G05286941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 10: Locating Bolts And Nuts
      G05286942Courtesy 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 11: Locating Injector Connectors
    G05286943Courtesy 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 12: Locating Wire Harness Clamps
      G05286944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 13: Locating Bolts And Nuts
      G05286945Courtesy 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 14: Locating Injector Connectors
    G05286946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FUEL INJECTOR ASSEMBLY
    1. Secure the delivery pipe between aluminum plates in a vise 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 clamp from the injector.
    3. Remove the O-ring, backup rings and E-ring from the fuel injector.
    Fig 15: Removing Fuel Injector Assembly
    G04947908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FUEL INJECTOR SEAL 
    1. Using the tips 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.
      • 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.
    Fig 16: Removing Fuel Injector Seal
    G04947909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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