Mike's Workshop Manuals: Service manuals for every vehicle
Home >> Lexus >> 2016 >> LS 460 Base, AWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System - Service Information >> FUEL INJECTOR (Direct Injection) >> Installation [09/2015 - ] >> Procedure

Installation [09/2015 - ]: Procedure

  1. INSTALL FUEL DELIVERY PIPE PLUG 
    1. Apply engine oil to the threaded portion of the fuel delivery pipe.
      NOTE:

      Make sure there is no gasoline on the threaded part of the fuel delivery pipe plug and fuel delivery pipe.

    2. Install 2 new gaskets and the 2 fuel delivery pipe plugs to the fuel delivery pipe and No. 2 fuel delivery pipe.

      Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

  2. INSTALL FUEL PIPE SUPPORT SUB-ASSEMBLY 
    1. Install 2 new O-rings, 2 new No. 1 backup rings, 2 new No. 2 backup rings and 2 new E-rings to the 2 fuel pipe support sub-assemblies as shown in the illustration.
      GTY394675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Backup Ring *2 No. 2 Backup Ring
      *3 O-Ring *4 E-Ring
      *a Alignment Opening *b Overlapped
      *c Stretched *d CORRECT
      *e INCORRECT - -
      NOTE:
      • Check that there is no foreign matter or damaged areas in the fuel pipe support sub-assembly O-ring groove.
      • Check that the No. 1 backup ring is installed in the correct direction.
      • Make sure that the backup rings and O-ring are installed in the correct order.
      • Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
    2. Apply engine oil to the O-ring.
      NOTE:

      Make sure there is no gasoline on the O-ring and inside the installation hole.

    3. Install the 2 fuel pipe support sub-assemblies to the fuel delivery pipe and No. 2 fuel delivery pipe with the 4 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  3. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the clean area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector assembly and its grooves.
      GTY639663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Clean Area
      NOTE:
      • Do not clean the tip of the fuel injector assembly.
      • Do not use a wire brush to clean the fuel injector assembly.
      • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.
    2. Apply engine oil to the fuel injector assembly contact surface of SST (guide). Then attach SST (guide) to the fuel injector assembly with the tapered inner portion facing the tip of the fuel injector assembly as shown in the illustration.
      GTY666621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03020
      TEXT IN ILLUSTRATION

      *1 SST (Guide)
      *a Tapered Inner Portion
    3. Install a new fuel injector seal to SST (holder).
      GTY619773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03010
      TEXT IN ILLUSTRATION

      *1 SST (Holder)
      *2 Fuel Injector Seal
      *a CORRECT
      *b INCORRECT
      NOTE:

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal and correcting this problem is very complicated.

    4. Install SST (holder with fuel injector seal) to the tip of the fuel injector assembly. Slide the seal downward into the fuel injector assembly groove (fuel injector assembly connector side) with your fingers as shown in the illustration.
      GTY676281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03010
        • 09268-03020
      TEXT IN ILLUSTRATION

      *1 SST (Holder)
      *2 SST (Guide)

      HINT: 

      Check that the seal covers the circumference of the fuel injector assembly groove as shown in the illustration.

    5. Using SST (holder), gently press downward on the fuel injector seal (fuel injector assembly connector side). Then slowly slide SST (guide) towards the fuel injector assembly tip to settle the seal into the fuel injector assembly groove.
      GTY636789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03010
        • 09268-03020
      TEXT IN ILLUSTRATION

      *1 SST (Holder)
      *2 SST (Guide)
      *3 Fuel Injector Seal
      *a Gently Press
      *b Slowly Slide
      *c CORRECT
      *d INCORRECT
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      HINT: 

      • When using SST (guide) to settle the fuel injector seal into the groove, SST (guide) only needs to be slid upward to the position labeled A in the illustration.
      • After using SST (guide) to settle the fuel injector seal into the groove, return SST (guide) to its position labeled B in the illustration.
    6. Install a new fuel injector seal to SST (holder).
      GTY619773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03010
      TEXT IN ILLUSTRATION

      *1 SST (Holder)
      *2 Fuel Injector Seal
      *a CORRECT
      *b INCORRECT
      NOTE:

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal and correcting this problem is very complicated.

    7. Install SST (holder with fuel injector seal) to the tip of the fuel injector assembly. Slide the fuel injector seal downward into the fuel injector assembly groove (fuel injector assembly tip side) with your fingers as shown in the illustration.
      GTY647118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03010
        • 09268-03020
      TEXT IN ILLUSTRATION

      *1 SST (Holder)
      *2 SST (Guide)
      *3 Fuel Injector Seal
      *a Welded Groove
      NOTE:

      Make sure that the fuel injector seal does not slip into the welded groove of the fuel injector assembly shown in the illustration. If it does, replace it with a new one.

      HINT: 

      Check that the fuel injector seal covers the circumference of the fuel injector assembly groove as shown in the illustration.

    8. Slowly slide SST (guide) towards the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the fuel injector seal into the fuel injector assembly groove.
      GTY620201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03020
      TEXT IN ILLUSTRATION

      *1 SST (Guide)
      *2 Fuel Injector Seal
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the seal if it becomes damaged.

      HINT: 

      • Set SST (guide) so that its bottom surface and the fuel injector seal are flush.
      • If it is difficult to slide SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.
    9. Using SST (holder), gently press downward on the fuel injector seal (fuel injector assembly tip side). Then slowly slide SST (guide) towards the fuel injector assembly tip to settle the fuel injector seal into the fuel injector assembly groove.
      GTY654552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03010
        • 09268-03020
      TEXT IN ILLUSTRATION

      *1 SST (Holder)
      *2 SST (Guide)
      *3 Fuel Injector Seal
      *a Gently Press
      *b Slide
      *c CORRECT
      *d INCORRECT
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

    10. Slowly slide SST (guide) towards the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the fuel injector seal into the fuel injector assembly groove.
      GTY661992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09260-39015 
        • 09268-03020
      TEXT IN ILLUSTRATION

      *1 SST (Guide)
      *2 Fuel Injector Seal
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      HINT: 

      • Set SST (guide) so that its bottom surface and the fuel injector seal's bottom surface are flush.
      • If it is difficult to slide SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.
    11. After installing the fuel injector seals, check that the fuel injector seals are not scratched, deformed or protruding from the fuel injector assembly grooves.
      GTY672281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

      TEXT IN ILLUSTRATION

      *a CORRECT
      *b INCORRECT
      *c Protruding
      *d Deformed
  4. INSTALL FUEL INJECTOR ASSEMBLY 

    HINT: 

    Perform "Inspection After Repairs" after replacing the fuel injector (Refer to INITIALIZATION [09/2015 - ] ).

    1. Install a new O-ring, new No. 1 backup ring, new No. 2 backup ring, new No. 3 backup ring and a new E-ring to the fuel injector assembly as shown in the illustration.
      GTY642047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Backup Ring *2 No. 2 Backup Ring
      *3 No. 3 Backup Ring *4 O-Ring
      *5 E-Ring - -
      *a Alignment Opening *b Overlapped
      *c Stretched *d CORRECT
      *e INCORRECT - -
      NOTE:
      • Check that there is no foreign matter or damaged areas in the fuel injector assembly O-ring groove.
      • Check that the No. 1 backup ring and No. 2 backup ring are installed in the correct direction.
      • Make sure that the No. 1 backup ring, No. 2 backup ring, No. 3 backup ring and O-ring are installed in the correct order.
      • Check that the alignment openings of the No. 1 backup ring, No. 2 backup ring and No. 3 backup ring are not overlapped or stretched as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
    2. Install the injector nozzle holder clamp.
      1. Apply engine oil to the O-ring. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the fuel delivery pipe.
        GTY145321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        GTY660069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Make sure there is no gasoline on the O-ring and inside the installation hole.
        • The fuel injector assembly connectors can be differentiated by the color of the insulators, which are black, yellow, green or brown. Install the fuel injector assemblies so that insulators are the same color for a given bank.
        • Make sure that there is no gap between the fuel delivery pipe and injector nozzle holder clamp.
        • Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the fuel delivery pipe.
        • Insert the fuel injector assembly straight into the fuel delivery pipe without tilting it.
        TEXT IN ILLUSTRATION

        *1 Insulator Color
  5. INSTALL NO. 2 FUEL DELIVERY PIPE 
    1. Install 4 new injector vibration insulators to the cylinder head.
    2. Apply lubricant to the fuel injector seal and installation holes.
    3. Install the No. 2 fuel delivery pipe (with fuel injector assemblies) to the cylinder head with the 5 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      NOTE:
      • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the cylinder head.
      • When inserting the No. 2 fuel delivery pipe, push it in evenly without tilting it.
    4. Connect the 4 fuel injector connectors.
    5. Connect the fuel pressure sensor connector.
  6. INSTALL FUEL DELIVERY PIPE 
    1. Install 4 new injector vibration insulators to the cylinder head.
    2. Apply lubricant to the fuel injector seal and installation holes.
    3. Install the fuel delivery pipe (with fuel injector assemblies) to the cylinder head with the 5 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      NOTE:
      • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage to the fuel injector assembly insertion hole of the cylinder head.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
    4. Connect the 4 fuel injector connectors.
    5. Connect the No. 3 fuel hose.
  7. INSTALL PCV HOSE 
    1. Install the PCV hose to the PCV valve.
  8. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Temporarily install the No. 4 fuel pipe sub-assembly.
      GTY617390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 19 mm union nut wrench, tighten the No. 4 fuel pipe sub-assembly in the order shown in the illustration.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      TEXT IN ILLUSTRATION

      *1 Union Nut Wrench
      *2 Separator Case
      *3 Fuel Pipe Protector
      NOTE:
      • After installing the No. 4 fuel pipe sub-assembly, check that the fuel pipe protector contacts with the separator case.
      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Refer to PRECAUTION [09/2015 - ] ).
  9. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH 
  10. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY 
  11. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
  12. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY 
    1. Install a new O-ring, new No. 1 backup ring, new No. 2 backup ring and new E-ring to the fuel injector assembly as shown in the illustration.
      GTY677925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Backup Ring *2 No. 2 Backup Ring
      *3 O-Ring *4 E-Ring
      *a Alignment Opening *b Overlapped
      *c Stretched *d CORRECT
      *e INCORRECT - -
      NOTE:
      • Check that there is no foreign matter or damaged areas in the fuel injector assemblies O-ring groove.
      • Check that the No. 1 backup ring and No. 2 backup ring are installed in the correct direction.
      • Make sure that the No. 1 backup ring, No. 2 backup ring and O-ring are installed in the correct order.
      • Check that the alignment openings of the No. 1 backup ring and No. 2 backup ring are not overlapped or stretched as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
    2. Apply engine oil to the O-ring.
      GTY146073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure there is no gasoline on the O-ring and inside the installation hole.

    3. Temporarily install the No. 3 fuel pipe sub-assembly to the fuel delivery pipe with the 2 bolts.
    4. Temporarily install the No. 3 fuel pipe sub-assembly to the fuel pump.
      GTY617316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the sealing surface of the No. 3 fuel pipe sub-assembly when temporarily installing the No. 3 fuel pipe sub-assembly.

    5. Tighten the 2 bolts in several passes.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    6. Using a 19 mm union nut wrench, tighten the union nut.
      GTY412380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      TEXT IN ILLUSTRATION

      *1 Union Nut Wrench
      NOTE:
      • There must be absolutely no free play in the union on the fuel pump side. If the union on the fuel pump side has free play, replace the fuel pump.
      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Refer to PRECAUTION [09/2015 - ] ).
    7. Connect the fuel pump connector.
  13. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY 

    HINT: 

    The installation procedures are the same as the No. 3 fuel pipe sub-assembly.

  14. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY 

    (Refer to INSTALLATION [09/2015 - ] )

scientia non olet · About Mike's Workshop Manuals