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Home >> Lexus >> 2012 >> IS 350 Base, AWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System (Service Information) >> Fuel Injector (For Direct Injection), Intake Manifold >> Removal >> Removal
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Fuel Injector (For Direct Injection), 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 MOLDING LH  . Refer to REMOVAL - Step 1
  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  . 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. REMOVE INTAKE AIR SURGE TANK  See step  19
  20. REMOVE INTAKE MANIFOLD 
    1. Disconnect the fuel tube from the delivery pipe sub-assembly.
      Fig 1: View Of Disconnecting Connector From Delivery Pipe Sub-Assembly
      GTY145981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. Disconnect the 4 connectors.
      Fig 2: Locating Connectors
      GTY100667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
      Fig 3: Locating Intake Manifold Bolts And Nuts
      GTY104873Courtesy 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
      GTY135765Courtesy 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
      GTY138136Courtesy 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: Location of No. 3 Fuel Hose
      GTY101538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 fuel hoses.
      Fig 7: Identifying Fuel Hoses, Pipe & Bolts
      GTY104874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and No. 1 fuel pipe.
  24. DISCONNECT NO. 2 FUEL PIPE  See step  24
  25. REMOVE FUEL PUMP ASSEMBLY  See step  25
  26. REMOVE NO. 2 FUEL PIPE 
    1. Remove the fuel pipe from the fuel delivery pipe.
      Fig 8: Identifying Fuel Pipe From Fuel Delivery Pipe
      GTY104879Courtesy 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.
  27. REMOVE NO. 3 FUEL PIPE 
    1. Remove the 4 bolts and fuel pipe from the fuel delivery pipe.
      Fig 9: Locating No. 3 Fuel Pipe Bolts
      GTY104065Courtesy 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: Locating Wire Harness Clamps
      GTY104875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 11: Identifying Bolts And Nuts
      GTY101972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the No. 2 fuel delivery pipe.
      Fig 12: Identifying Injector Connectors
      GTY101733Courtesy 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 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
      GTY103927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 nuts.
      Fig 14: Locating Bolts And Nuts
      GTY100966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the No. 1 fuel delivery pipe.
      Fig 15: Locating Injector Connectors
      GTY104878Courtesy 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.
  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.
      Fig 16: 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.
  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: 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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