Removal

2GR-FSE FUEL: FUEL INJECTOR (for Direct Injection): REMOVAL

REMOVAL

1. PRECAUTION Removal
2. DISCHARGE FUEL SYSTEM PRESSURE Removal
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 COOL AIR INTAKE DUCT SEAL Removal
5. REMOVE ENGINE ROOM SIDE COVER LH Removal
6. REMOVE ENGINE ROOM SIDE COVER RH Removal
7. REMOVE V-BANK COVER SUB-ASSEMBLY Removal
8. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH Removal
9. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH Removal
10. REMOVE FRONT FENDER TO COWL SIDE SEAL LH Removal
11. REMOVE FRONT FENDER TO COWL SIDE SEAL RH Removal
12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal
13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal
14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal
15. DRAIN ENGINE COOLANT Service and Repair
16. DISCONNECT NO. 2 VENTILATION HOSE Removal
17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal
18. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY Removal
19. REMOVE INTAKE AIR SURGE TANK Removal
20. REMOVE INTAKE MANIFOLD

(a) Disconnect the fuel tube from the delivery pipe sub-assembly.
- 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.

(b) Disconnect the 4 connectors.

(a) Remove the bolt and disconnect the water hose joint.
22. REMOVE FUEL PRESSURE PULSATION DAMPER Removal
23. REMOVE NO. 1 FUEL PIPE

(a) Disconnect the No. 3 fuel hose from the No. 1 fuel pipe.

(b) Disconnect the 2 fuel hoses.
(c) Remove the 2 bolts and No. 1 fuel pipe.
24. DISCONNECT NO. 2 FUEL PIPE Removal
25. REMOVE FUEL PUMP ASSEMBLY Removal
26. REMOVE NO. 2 FUEL PIPE

(a) 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.

(b) Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.
27. REMOVE NO. 3 FUEL PIPE

(a) 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.

(b) Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.
28. REMOVE NO. 2 FUEL DELIVERY PIPE

(a) Disconnect the 3 wire harness clamps.

(b) Remove the 2 bolts and 2 nuts.

(c) With the connectors still connected, disconnect the No. 2 fuel delivery pipe.
- 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.

(d) Disconnect the 3 injector connectors.
(e) Remove the 3 injector vibration insulators from the cylinder head.
29. REMOVE NO. 1 FUEL DELIVERY PIPE

(a) Disconnect the 2 wire harness clamps and fuel pressure sensor connector.

(b) Remove the 2 bolts and 2 nuts.

(c) With the connectors still connected, disconnect the No. 1 fuel delivery pipe.
- 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.

(d) Disconnect the 3 injector connectors.
(e) Remove the 3 injector vibration insulators from the cylinder head.
30. REMOVE FUEL INJECTOR ASSEMBLY

(a) Secure the delivery pipe between aluminum plates in a vise and pull out the injector in a straight line.
- 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.

(b) Remove the nozzle holder clamp from the injector.
(c) Remove the O-ring, backup rings and E-ring from the fuel injector.
31. REMOVE FUEL INJECTOR SEAL

(a) 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.
- 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.

(b) Remove the 2 injector seals from the injector.