Fuel Injector: Service and Repair

Injector:

REMOVAL
1. REMOVE AIR CLEANER HOSE
2. REMOVE AIR INTAKE CHAMBER ASSEMBLY




3. DISCONNECT INJECTOR CONNECTORS




4. REMOVE AIR ASSIST HOSES AND PIPE
a. Disconnect the air assist pipe from the bracket on the No.1 fuel pipe.
b. Remove the air assist hoses from the intake manifold.

5. DISCONNECT FUEL INLET PIPE




a. Remove the fuel hose clamp.




b. Disconnect the fuel inlet pipe (fuel tube connector) from the fuel filter.

CAUTION:
- Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions.
- As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment.




6. REMOVE DELIVERY PIPES AND INJECTORS

NOTE:
- Be careful not to drop the injectors when removing the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.

a. Remove the 5 bolts and delivery pipes together with the 6 injectors and fuel pipe.
b. Remove the 4 spacers from the intake manifold.
c. Pull out the 6 injectors from the delivery pipes.
d. Remove the 2 O-ring and 2 grommets from each injector.

INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES




a. Install new insulator and grommet to each injector.
b. Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector.




c. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches an O-ring of the injector.
d. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors.
e. Position the injector connector outward.




f. Place the 4 spacers in position on the intake manifold.




g. Apply a light coat of spindle oil or gasoline on the place where a intake manifold touches an O-ring of the injector.
h. Place the delivery pipes and fuel pipe together with the 6 injectors in position on the intake manifold.
i. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold.
j. Temporarily install the bolt holding the fuel pipe to the intake manifold.




k. Check that the injectors rotate smoothly.

HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

l. Position the injector connector outward.




m. Tighten the 4 bolts holding the delivery pipes to the intake manifold.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

n. Tighten the bolt holding the fuel pipe to the intake manifold

Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf)

2. CONNECT FUEL INLET PIPE




a. Align the alignment marks (white paint) on the fuel inlet pipe.




b. Connect the fuel inlet pipe (fuel tube connector) to the fuel tube.

CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions.




c. Install the fuel hose clamp to the fuel tube.




3. INSTALL AIR ASSIST HOSES AND PIPE
a. Connect the air assist hoses to the intake manifold
b. Install the air assist pipe.

4. CONNECT INJECTOR CONNECTORS
5. INSTALL AIR INTAKE CHAMBER ASSEMBLY
6. INSTALL AIR CLEANER HOSE
7. CHECK FOR FUEL LEAKS

FUEL SYSTEM



a. Observe these precautions when disconnecting the fuel tube connector (quick type).
1. Remove the fuel pipe clamp.
2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.




3. Be sure to disconnect with hands.
4. When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time.
5. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.





HINT: When the connector and the pipe are stuck, pinch the fuel pipe between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time.

6. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.




7. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.




b. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
1. Connect the LEXUS hand-held tester or OBD II scan tool to the DLC3.
2. Turn the ignition switch ON and push LEXUS hand-held tester or OBDII scan tool main switch ON.

NOTE: Do not start the engine.

3. Select the active test mode on the LEXUS hand-held tester or OBDII scan tool.
4. Please refer to the LEXUS hand-held tester or OBDII scan tool operator's manual for further details.
5. If you have no LEXUS hand-held tester or OBD II scan tool, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.
6. Check that there are no leaks from any part of the fuel system.
7. Turn the ignition switch to LOCK.
8. Disconnect the LEXUS hand-held tester or OBD II scan tool from the DLC3.