Removal

2UR-GSE FUEL: FUEL INJECTOR (for Direct Injection): REMOVAL

1. PRECAUTION

CAUTION:
* Do not smoke or work near an open flame when handling the fuel system.
* Keep gasoline away from rubber or leather parts.
* Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump assembly and the fuel injector assembly. The fuel in the pipe is highly pressurized.
2. DISCHARGE FUEL SYSTEM PRESSURE

(a) Discharge fuel system pressure Service Precautions.

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

(a) Remove the intake air surge tank assembly Removal.

5. REMOVE NO. 1 FUEL HOSE Removal

6. SEPARATE ENGINE WIRE Removal

7. REMOVE NO. 3 COVER SUB-ASSEMBLY Removal

8. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (for Direct Injection)

(a) Remove the fuel pressure pulsation damper assembly and No. 1 fuel pipe sub-assembly Removal.

9. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY Removal

10. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY Removal

11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Remove the No. 1 engine cover sub-assembly.





12. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH

(a) Remove the No. 2 engine cover sub-assembly LH.





13. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

(a) Using a 19 mm union nut wrench, remove the No. 4 fuel pipe sub- assembly.





14. REMOVE SEPARATOR CASE

(a) Disconnect the fuel pressure sensor connector.





(b) Remove the 4 bolts and separator case from the cylinder head.





15. REMOVE NO. 2 FUEL DELIVERY PIPE (for Direct Injection)

(a) Disconnect the 4 injector connectors.





(b) Remove the 5 bolts and the No. 2 fuel delivery pipe from the cylinder head.





NOTICE:
* Be extremely careful not to touch or strike the tips of the injectors.
* Pull the fuel delivery pipe straight without tilting it.

(c) Remove the 4 injector vibration insulators from the cylinder head.





16. REMOVE FUEL DELIVERY PIPE (for Direct Injection)

(a) Disconnect the 4 injector connectors.





(b) Remove the 5 bolts and the fuel delivery pipe from the cylinder head.





NOTICE:
* Be extremely careful not to touch or strike the tips of the injectors.
* Pull the fuel delivery pipe straight without tilting it.

(c) Remove the 4 injector vibration insulators from the cylinder head.





17. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)

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





NOTICE:
* Pull the fuel injector assembly straight out to avoid damage to the seal surface of the fuel delivery pipe and No. 2 fuel delivery pipe O-ring.
* For reinstallation, attach a tag or label to the injector shaft.

(b) Remove the nozzle holder clamp from the fuel injector assembly.





(c) Remove the O-ring, backup rings (No. 1, No. 2 and No. 3) and E-ring from the fuel injector.

18. REMOVE FUEL INJECTOR SEAL

(a) Using the tips of needle-nose pliers, pinch and pull one of the 2 fuel injector seals at several points to stretch it. Repeat this for the other fuel injector seal.





NOTICE:
* Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.
* If an injector is dropped or the tip of an fuel injector assembly is struck, replace it with a new one.

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