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Fuel Injector, Intake Manifold: Removal: Removal

  1. REMOVE COOL AIR INTAKE DUCT SEAL  . Refer to REMOVAL - Step 1
  2. REMOVE ENGINE ROOM SIDE COVER LH  . Refer to REMOVAL - Step 2
  3. REMOVE ENGINE ROOM SIDE COVER RH  . Refer to REMOVAL - Step 3
  4. REMOVE V-BANK COVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 4
  5. REMOVE FRONT UPPER FENDER PROTECTOR LH  . Refer to REMOVAL - Step 4
  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  . Refer to REMOVAL - Step 1
  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  . Refer to REMOVAL - Step 8
  10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  . Refer to REMOVAL - Step 9
  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  . Refer to REMOVAL - Step 10
  12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 11
  13. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT: 

    Refer to PRECAUTION .

  14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  15. DRAIN ENGINE COOLANT  . Refer to ON-VEHICLE INSPECTION - Step 4
  16. DISCONNECT NO. 2 VENTILATION HOSE  . Refer to REMOVAL - Step 5
  17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE  . Refer to REMOVAL - Step 6
  18. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY  . Refer to REMOVAL - Step 7
  19. SEPARATE COLD START INJECTOR 
    1. Disconnect the cold start injector connector.
      Fig 1: View Of Cold Start Injector
      GTY143843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the 2 bolts and cold start injector.
  20. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the vacuum hose from the intake air surge tank.
      Fig 2: View Of No. 1 Vacuum Switching Valve Assembly To Intake Air Surge Tank
      GTY146268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the purge VSV from the intake air surge tank.
    3. Disconnect the wire harness and hose from the surge tank.
      Fig 3: View Of Wire Harness & Hose To Intake Air Surge Tank
      GTY146146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the ventilation hose from the intake air surge tank.
      Fig 4: View Of Ventilation Hose To Intake Air Surge Tank
      GTY136490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and water hose joint from the intake air surge tank.
      Fig 5: View Of Connecting Water Hose Joint
      GTY134091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and disconnect the surge tank stay.
      Fig 6: View Of Disconnecting Surge Tank Stay
      GTY127516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.
      Fig 7: View Of Removing Bolts & Nuts
      GTY131473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INTAKE MANIFOLD 
    1. Disconnect the connector for the SCV.
    2. Disconnect the SCV position sensor connector.
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
      Fig 8: View Of Installing Intake Manifold
      GTY136797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT WATER HOSE JOINT 
    1. Remove the bolt and water hose joint.
      Fig 9: Identifying Water Hose Joint
      GTY135765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FUEL PRESSURE PULSATION DAMPER 
    1. Using SST, remove the fuel pressure pulsation damper from the fuel pump.
      Fig 10: View Of Removing Fuel Pressure Pulsation Damper
      GTY138136Courtesy 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 11: Location of No. 3 Fuel Hose
      GTY101538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 fuel hoses.
      Fig 12: View Of Installing No. 1 Fuel Pipe
      GTY146052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and No. 1 fuel pipe.
  25. DISCONNECT NO. 2 FUEL PIPE  See step  25
  26. REMOVE FUEL PUMP ASSEMBLY  See step  26
  27. REMOVE NO. 2 FUEL PIPE 
    1. Remove the fuel pipe from the fuel delivery pipe.
      Fig 13: Identifying No. 2 Fuel Pipe Sub-Assembly
      GTY124935Courtesy 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 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.
      Fig 14: View Of Removing No. 3 Fuel Pipe
      GTY145305Courtesy 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 from the No. 3 fuel pipe.
  29. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the 3 wire harness clamps.
      Fig 15: View Of Removing Wire Harness Clamps
      GTY140373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
    3. With the connectors still connected, disconnect the delivery pipe.
      Fig 16: Disconnecting Delivery Pipe
      GTY141431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  30. REMOVE NO. 1 FUEL DELIVERY PIPE 
    1. Disconnect the 2 wire harness clamps.
      Fig 17: View Of Removing Wire Harness Clamps
      GTY126587Courtesy 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 18: View Of Removing No. 1 Fuel Delivery Pipe
      GTY141015Courtesy 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 connectors from the 3 injectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
  31. REMOVE FUEL INJECTOR 
    1. Secure the delivery pipe in a vise between aluminum plates and pull out the injector in a straight line.
      Fig 19: View Of Attaching Tag Or Label To Injector Shaft
      GTY146398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  32. 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 20: View Of Removing Fuel Injector Seal
      GTY103932Courtesy 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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