2005 Lexus SC 430FACTORY OEM SERVICE PROCEDURE

Fuel Injector ASSY: Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION   ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  3. REMOVE V-BANK COVER 
    1. Remove the 2 nuts and V-bank cover.
  4. REMOVE INTAKE AIR CONNECTOR PIPE 
    1. Disconnect the air hose and ventilation hose No. 1.
    2. Loosen the 2 hose clamps and remove the bolt and intake air connector.
  5. REMOVE V-BANK COVER BRACKET NO. 1 
    1. Remove the bolt and bracket.
  6. REMOVE V-BANK COVER BRACKET NO. 2 
    1. Remove the bolt and bracket.
  7. REMOVE V-BANK COVER BRACKET NO. 3 
    1. Remove the bolt and bracket.
  8. REMOVE V-BANK COVER BRACKET NO. 4 
    1. Remove the 2 bolts and bracket.
  9. REMOVE VACUUM SWITCHING VALVE ASSY 
    1. Disconnect the hose and connector and remove the bolt and VSV.
  10. REMOVE ENGINE WIRE 
    1. Disconnect the 2 wire clamps from the wire clamp brackets on the RH delivery pipe.
      Fig 1: Disconnecting Wire Clamps From Wire Clamp Brackets On RH Delivery Pipe
      G02958607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Disconnect the fuel delivery pipe and fuel pipe by removing right and left pulsation dampers.
    2. Remove the 4 gaskets.
  12. REMOVE FUEL DELIVERY PIPE SUB-ASSY 
    1. Remove the installation bolts of the water by-pass pipe No. 1 and No. 2.
    2. Disconnect the injector connectors.
    3. Remove the 2 nuts. Then remove the fuel delivery pipe No. 1 by pulling it straight upward holding both ends.
  13. REMOVE FUEL DELIVERY PIPE SUB-ASSY NO. 2 
    1. Disconnect the injector connectors.
    2. Remove the 2 nuts. Then remove the fuel delivery pipe No. 2 by pulling it straight upward holding both ends.
      Fig 2: Removing Fuel Delivery Pipe Sub-Assy No. 2
      G02958608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL INJECTOR ASSY 
    1. Remove the injector from the intake manifold.
      NOTE: Pull upward on the injector. Adding force in the horizontal direction may cause the O-ring to become 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 the injector's grooves (where O- rings are installed) for foreign matter or damage. Apply gasoline to 2 new O-rings and install them to the injector's grooves.
      Fig 3: Installing O-Rings To Injector's Groove
      G02958609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth. Position the injector connector outward.
      Fig 4: Pushing Fuel Injector While Twisting Back & Forth
      G02958610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the injector rotates smoothly.
    NOTE: If the injector does not rotate smoothly, the O-ring may be caught on something. Remove the injector, replace the O-ring and reinstall the injector.
  16. INSTALL FUEL DELIVERY PIPE SUB-ASSY NO. 2 
    1. Install the injector (with delivery pipe) to the intake manifold. Then position the injector connector so that it faces outward.
    2. Check that the injectors rotate smoothly within a range of approximately 45°.

      HINT:

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

    3. Set a new spacer on the intake manifold, and install the delivery pipe to the intake manifold with the 2 nuts.

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

      Fig 5: Installing Fuel Delivery Pipe Sub-Assy No. 2
      G02958611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FUEL DELIVERY PIPE SUB-ASSY 
    1. Install the injector (with delivery pipe) to the intake manifold and then position the injector connector so that it faces outward.
    2. Check that the injectors rotate smoothly. Turn the injector both ways by approximately 45 degrees.

      HINT:

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

    3. Set a new spacer on the intake manifold, and install the delivery pipe to the intake manifold with the 2 nuts.

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

  18. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY 
    1. Set new upper and lower gaskets into the fuel main hose, and insert the pulsation damper through the hose and gaskets.
    2. Install the pulsation damper to the fuel delivery pipe No. 2.

      SST 09612-24014 (09617-24011)

      Torque: 

      • 39 N.m (398 kgf.cm, 29 ft.lbf) 
      • 33 N.m (337 kgf.cm, 24 ft.lbf) for use with SST 
      Fig 6: Installing Fuel Pressure Pulsation Damper Assy
      G02958612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL ENGINE WIRE 
    1. Connect the 2 wire clamps to the wire clamp brackets on the RH delivery pipe.
      Fig 7: Installing Engine Wire
      G02958613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL VACUUM SWITCHING VALVE ASSY 
    1. Install the VSV with the bolt.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

    2. Connect the hose and connector.
  21. INSTALL V-BANK COVER BRACKET NO. 4 
    1. Install the bracket with the 2 bolts.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

  22. INSTALL V-BANK COVER BRACKET NO. 3 
    1. Install the bracket with the bolt.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

  23. INSTALL V-BANK COVER BRACKET NO. 2 
    1. Install the bracket with the bolt.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

  24. INSTALL V-BANK COVER BRACKET NO. 1 
    1. Install the bracket with the bolt.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

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

      Torque: 

      • 4.0 N.m (41 kgf.cm, 35 in.lbf) for hose clamp 
      • 5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt 
    2. Connect the air hose and the ventilation hose No. 1.
  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  27. PERFORM INITIALIZATION (See  INITIALIZATION  ) 
    NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  28. CHECK FOR FUEL LEAKS (See  PRECAUTION   ) 
  29. INSTALL V-BANK COVER 
    1. Install the V-bank cover with the 2 nuts.

      Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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