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Fuel Injector, Intake Manifold: Removal

  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 PRECAUTION  .

  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. SEPARATE COLD START INJECTOR 
    1. Disconnect the cold start injector connector.
    2. Separate the 2 bolts and cold start injector.
      Fig 1: Locating Bolts And Cold Start Injector
      G05826503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the vacuum hose from the intake air surge tank.
    2. Remove the bolt and disconnect the purge VSV from the intake air surge tank.
      Fig 2: Locating Bolt And Purge VSV
      G05826504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the wire harness and hose from the surge tank.
      Fig 3: Locating Wire Harness And Hose
      G05826505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the ventilation hose from the intake air surge tank.
      Fig 4: Locating Ventilation Hose
      G05826506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and water hose joint from the intake air surge tank.
      Fig 5: Locating Bolt And Water Hose Joint
      G05826507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and disconnect the surge tank stay.
      Fig 6: Locating Bolt And Surge Tank Stay
      G05826508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.
      8. Fig 7: Locating Bolts, Nuts And Gasket
      G05826509Courtesy 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: Locating Bolts, Nuts, Intake Manifold And Gasket
      G05826510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT WATER HOSE JOINT 
    1. Remove the bolt and water hose joint.
      Fig 9: Locating Bolt And Water Hose Joint
      G05826317Courtesy 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: 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 11: 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 12: Locating Bolts And No. 1 Fuel Pipe
      G05826514Courtesy 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.
    2. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.
      Fig 13: Identifying No. 2 Fuel Pipe
      G05826515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 14: Locating Bolts And Fuel Pipe
      G05826516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 2 FUEL DELIVERY PIPE 
    1. Disconnect the 3 wire harness clamps.
    2. Remove the 2 bolts and 2 nuts.
      Fig 15: Locating Bolts And Nuts
      G05826517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With the connectors still connected, disconnect the 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 16: Identifying Delivery Pipe Connectors
        G05826518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    2. Remove the 2 bolts and 2 nuts.
      Fig 17: Locating No. 1 Fuel Delivery Pipe Bolts And Nuts
      G05826519Courtesy 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 connectors from the 3 injectors.
    5. Remove the 3 injector vibration insulators from the cylinder head.
      Fig 18: Identifying No. 1 Fuel Delivery Pipe
      G05826520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FUEL INJECTOR 
    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 19: 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.
  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.
      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 20: Removing Injector Seals From Injector
      G04947909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 injector seals from the injector.
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