2008 Lexus IS FFACTORY OEM SERVICE PROCEDURE

FUEL PRESSURE PULSATION DAMPER (for Direct Injection): Installation

  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 and the fuel injector. The fuel in the pipe is highly pressurized.
  2. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (for Direct Injection) 
    1. Temporarily install the 2 fuel pressure pulsation damper assemblies together with 4 new gaskets and the No 1 fuel pipe sub-assembly.
      Fig 1: Identifying Fuel Pressure Pulsation Damper And Fuel Pipe
      G05750025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 clamp bolts

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

      Fig 2: Locating Clamp Bolts
      G05750023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, tighten the 2 fuel pressure pulsation damper assemblies

      SST 09612-24014 (09617-24011) 

      Torque: without SST 

      40 N*m (408 kgf*cm, 30 ft.*lbf) 

      with SST 

      35 N*m (357 kgf*cm, 26 ft.*lbf) 

      HINT

      • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.)
      • Make sure that SST and the wrench are connected in a straight line
      Fig 3: Identifying Torque Wrench Fulcrum Length
      G05750027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 3 fuel hoses
      Fig 4: Locating Fuel Hoses
      G05750021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 brackets with the 2 bolts and then connect the harness clamp.

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

      Fig 5: Locating Brackets Bolts
      G05750020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 3 COVER SUB-ASSEMBLY 
    1. Install the No. 3 cover sub-assembly with the 2 clips.
      Fig 6: Identifying Cover Clips
      G05750019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bracket and wire harness with the 3 bolts.

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

    Fig 7: Locating Wire Harness And Bracket Bolts
    G05750018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL ENGINE WIRE 
    1. Connect the harness clamp then install the engine wire.
    Fig 8: Identifying Harness Clamp
    G05750017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT NO. 1 FUEL HOSE  (See INSTALLATION )
  6. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    1. Install the intake air surge tank assembly (See INSTALLATION )
  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  8. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
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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.