Removal

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

1. REMOVE COOL AIR INTAKE DUCT SEAL Removal

2. REMOVE ENGINE ROOM SIDE COVER LH Removal

3. REMOVE ENGINE ROOM SIDE COVER RH Removal

4. REMOVE V-BANK COVER SUB-ASSEMBLY Removal

5. REMOVE FRONT UPPER FENDER PROTECTOR LH 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 MOULDING LH

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 Removal

10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

13. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.

14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

15. DRAIN ENGINE COOLANT Testing and Inspection

16. DISCONNECT NO. 2 VENTILATION HOSE Removal

17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal

18. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY Removal

19. REMOVE INTAKE AIR SURGE TANK Removal

20. REMOVE INTAKE MANIFOLD

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

NOTICE:
* 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.

21. REMOVE WATER HOSE JOINT

(a) Remove the bolt and disconnect the water hose joint.

22. REMOVE FUEL PRESSURE PULSATION DAMPER

(a) Using SST, remove the fuel pressure pulsation damper from the fuel pump.

SST : 09612-24014

09617-24011

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.

NOTICE:
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.

NOTICE:
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 to 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.

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 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.

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 injector connectors.

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

30. 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's 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.

31. 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.