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Fuel Injector ASSY: Replacement

WARNING: This page is about a different car, the 2004 Lexus SC 430, 2003 Lexus SC 430, and 2002 Lexus SC 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION  ) 
  2. REMOVE V-BANK COVER 
    1. Remove the V-bank cover by removing the 2 nuts.
  3. REMOVE AIR CLEANER INLET NO.1 
  4. REMOVE INTAKE AIR CONNECTOR PIPE 
    1. Disconnect the air hose and ventilation hose No.1.
    2. Remove the intake air connector pipe by removing the bolt and hose clamp.
  5. REMOVE V-BANK COVER BRACKET NO.1 
  6. REMOVE V-BANK COVER BRACKET NO.2 
  7. REMOVE V-BANK COVER BRACKET NO.3 
  8. REMOVE V-BANK COVER BRACKET NO.4 
  9. REMOVE VACUUM SWITCHING VALVE ASSY 
  10. SEPARATE ENGINE WIRE 
  11. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Disconnect the fuel delivery pipe and the fuel pipe by removing the both of right and left pulsation dampers.
    2. Remove the gasket.
  12. REMOVE FUEL DELIVERY PIPE SUB-ASSY 
    1. Remove the installation bolts of the water bypass pipe No.1 and No.2.
    2. Disconnect the connector.
    3. Remove the 2 bolts, then the fuel delivery pipe No.1 by pulling it straight upward holding the both ends.
      Fig 1: Removing Fuel Delivery Pipe Sub-Assy
      G00935550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. FUEL DELIVERY PIPE SUB-ASSY NO.2 
    1. Disconnect the connector.
    2. Remove the 2 bolts, then the fuel delivery pipe No.2 by pulling it straight upward holding the both ends.
  14. REMOVE FUEL INJECTOR ASSY 
    1. Remove the injector from the intake manifold.
      NOTE: Do not put any force to the injector in the horizontal direction, because the O-ring might be stuck. 
    2. Remove the O-ring, grommet and vibration insulator from the injector.
  15. INSTALL FUEL INJECTOR ASSY 
    1. Install a new grommet and vibration insulator to the injector.
    2. Check that there is no foreign object stuck nor damage in the groove of the O-ring of the injector. Apply some gasoline to new O-ring, and install it to the injector.
    3. Install the injector to the delivery pipe, rotating the injector both ways.
    4. Check that the injector can rotate smoothly.
      Fig 2: Installing Fuel Injector Assy
      G00935551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When the injector cannot rotate smoothly, the O-ring might engage with something. In case of that, the operation should be started after the injector has been removed then the O-ring has been replaced with a new one once again. 
  16. INSTALL FUEL DELIVERY PIPE SUB-ASSY NO.2 
    1. Install the injector with delivery pipe to the intake manifold.
    2. Under the above condition, turn the injector both ways by approximately 45 degrees.
    3. Inserting a spacer in between, install the delivery pipe with injector by 2 bolts.

      Torque: 21 N.m (204kgf.cm, 14 ft.lbf) 

  17. INSTALL FUEL DELIVERY PIPE SUB-ASSY 
    1. Install the injector with delivery pipe to the intake manifold.
    2. Under the above condition, turn the injector both ways by approximately 45 degrees.
    3. Inserting a spacer in between, install the delivery pipe with injector by 2 bolts.

      Torque: 21 N.m (204 kgf.cm, 14 ft.lbf) 

  18. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Inserting 2 new gaskets in between, install the fuel main hose the fuel pressure pulsation damper.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

      Fig 3: Inserting Gaskets In Between & Fuel Main Hose
      G00935552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL ENGINE WIRE 
  20. INSTALL VACUUM SWITCHING VALVE ASSY 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  21. INSTALL V-VANK COVER BRACKET NO.4 

    Torque: 7.5 N.m (80 kgf.cm,66 in.lbf) 

  22. INSTALL V-BANK COVER BRACKET NO.3 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  23. INSTALL V-BANK COVER BRACKET NO.2 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  24. INSTALL V-BANK COVER BRACKET NO.1 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  25. INSTALL INTAKE AIR CONNECTOR PIPE 
    1. Install the intake air connector pipe with the bolt and the hose clamp.

      Torque: 

      4 N.m (40 kgf.cm, 35 in.lbf) (hose clamp) 

      5 N.m (50 kgf.cm, 44 in.lbf) (bolt) 

    2. Connect the air hose and the ventilation hose NO. 1 together.
  26. INSTALL AIR CLEANER INLET NO.1 
  27. INSPECT FUEL LEAK 
  28. INSTALL V-BANK COVER 

    Torque: 5 N.m (50 kgf.cm, 44 in.lbf) 

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