Removal

4GR-FSE FUEL: FUEL INJECTOR: REMOVAL

1. PRECAUTION (W/ Navigation System for HDD)

NOTICE:
After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

2. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

4. REMOVE INTAKE MANIFOLD

HINT
Removal.

5. DISCONNECT WATER HOSE JOINT

(a) Remove the bolt and water hose joint.





6. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY Removal

7. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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





(b) Disconnect the 2 fuel hoses.





(c) Remove the 2 bolts and No. 1 fuel pipe sub-assembly.

8. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Removal

9. REMOVE FUEL PUMP ASSEMBLY Removal

10. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Remove the fuel pipe from the fuel delivery pipe.





NOTICE:
Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe O-ring.

(b) Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.

11. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY

(a) Remove the 4 bolts and fuel pipe from the fuel delivery pipe.





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NOTICE:
Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe O-rings.

(b) Remove the O-rings, backup rings and E-rings from the No. 3 fuel pipe.

12. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Disconnect the 3 wire harness clamps.





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(b) Remove the 2 bolts and 2 nuts.

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





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NOTICE:
* 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 connectors from the 3 injectors.

(e) Remove the 3 injector vibration insulators from the cylinder head.

13. REMOVE NO. 1 FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Disconnect the 2 wire harness clamps.





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(b) Remove the 2 bolts and 2 nuts.

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





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NOTICE:
* 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 connectors from the 3 injectors.

(e) Remove the 3 injector vibration insulators from the cylinder head.

14. REMOVE FUEL INJECTOR ASSEMBLY

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





NOTICE:
* Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe O-ring.
* For reinstallation, attach a tag or label to the injector shaft.
(b) Remove the nozzle holder clamps from the injectors.

(c) Remove the O-ring, backup rings and E-ring from the fuel injector.

15. REMOVE FUEL INJECTOR SEAL

(a) 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.





NOTICE:
* 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.