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

  1. PRECAUTION  (See FUEL INJECTOR (FOR PORT INJECTION) )
  2. DISCHARGE FUEL SYSTEM PRESSURE  (See FUEL SYSTEM )
  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 SERVICE PLUG GRIP  (See REMOVAL )
  5. REMOVE COOL AIR INTAKE DUCT SEAL  (See REMOVAL )
  6. REMOVE ENGINE ROOM SIDE COVER LH  (See REMOVAL )
  7. REMOVE ENGINE ROOM SIDE COVER RH  (See REMOVAL )
  8. REMOVE V-BANK COVER SUB-ASSEMBLY  (See REMOVAL )
  9. REMOVE FRONT UPPER FENDER PROTECTOR LH  (See REMOVAL )
  10. REMOVE FRONT UPPER FENDER PROTECTOR RH  (See REMOVAL )
  11. REMOVE FRONT FENDER TO COWL SIDE SEAL LH  (See REMOVAL )
  12. REMOVE FRONT FENDER TO COWL SIDE SEAL RH  (See REMOVAL )
  13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  14. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  16. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  17. DISCONNECT NO. 2 VENTILATION HOSE  (See REMOVAL )
  18. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE  (See REMOVAL )
  19. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY  (See REMOVAL )
  20. REMOVE INTAKE AIR SURGE TANK  (See REMOVAL )
  21. 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 Delivery Pipe Connectors
      G05286934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
    Fig 3: Locating Intake Manifold And Gasket Bolts With Nuts
    G05286935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE WATER HOSE JOINT 
    1. Remove the bolt and disconnect the water hose joint.
    Fig 4: Identifying Water Hose Joint Bolt
    G05286936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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
  24. 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 From No. 1 Fuel Pipe
      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 No. 1 Fuel Pipe Hose And Bolts
      G05286938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT NO. 2 FUEL PIPE  (See REMOVAL )
  26. REMOVE FUEL PUMP ASSEMBLY  (See REMOVAL )
  27. 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.
      Fig 8: Identifying Fuel Pipe From Fuel Delivery Pipe
      G05286939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.
  28. 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 9: Locating No. 3 Fuel Pipe Bolts
    G05286940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the 3 wire harness clamps.
      Fig 10: Locating 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 Fuel Delivery Pipe Injector Connectors
      G05286943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 3 injector connectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
  30. 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
      G05286944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
    3. With the connectors still connected, disconnect the No. 1 fuel delivery pipe.
      Fig 14: Locating No. 1 Fuel Delivery Pipe Bolts And Nuts
      G05286945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 Injector Connectors
    G05286946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. 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.
      Fig 16: Pulling Out Injector
      G04947908Courtesy 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.
  32. 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 17: Removing Injector Seals From Injector
    G04947909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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