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Home >> Lexus >> 2008 >> IS 250 RWD, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 59 (Fuel (2GR-FSE)) >> Fuel Injector (For Direct Injection), Intake Manifold >> Removal

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

WARNING: This page is about a different car, the 2008 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 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 REMOVAL )
  10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  13. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See FUEL SYSTEM .

  14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  15. DRAIN ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  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 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: Disconnecting Fuel Tube From Delivery Pipe Sub-Assembly
      G05285931Courtesy 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 Bolts And Nuts
    G05286935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE WATER HOSE JOINT 
    1. Remove the bolt and disconnect the water hose joint.
    Fig 4: Locating Water Hose Joint Bolt
    G05826317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL PRESSURE PULSATION DAMPER 
    1. Using SST, remove the fuel pressure pulsation damper from the fuel pump.

    SST 09612-24014(09617-24011) 

    Fig 5: Removing Fuel Pressure Pulsation Damper From Fuel Pump
    G05286981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 1 FUEL PIPE 
    1. Disconnect the No. 3 fuel hose from the No. 1 fuel pipe.
      Fig 6: Locating No. 3 Fuel Hose
      G05286937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 fuel hoses.
    3. Remove the 2 bolts and No. 1 fuel pipe.
      4. Fig 7: Locating Bolts And No. 1 Fuel Pipe
      G05286938Courtesy 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: 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.
      Fig 9: Locating Fuel Pipe Bolts
      G05286940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Locating No. 2 Fuel Delivery Pipe Wire Harness Clamps
      G05286941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 11: Locating No. 2 Fuel Delivery Pipe 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.
      Fig 12: Locating No. 2 Fuel Delivery Pipe Connectors
      G05286943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 3 injector connectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
  29. REMOVE NO. 1 FUEL DELIVERY PIPE 
    1. Disconnect the 2 wire harness clamps and fuel pressure sensor connector.
      Fig 13: Locating Wire Harness Clamps And Fuel Pressure Sensor Connector
      G05826326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 14: 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 15: Locating No. 1 Fuel Delivery Pipe Connectors
    G05286946Courtesy 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.
      Fig 16: Attaching Tag Or Label To Injector Shaft
      G05826329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nozzle holder clamps from the injectors.
    3. Remove the O-ring, backup rings and E-ring from the fuel injector.
  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.
      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.
        Fig 17: Removing Injector Seals From Injector
        G04947909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 injector seals from the injector.
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