ES300 1992-1997

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



Specific to:

Lexus ES300 1992-1993

  1. Disconnect the negative battery cable.
  2.  
  3. Drain engine coolant
  4.  
  5. Disconnect accelerator cable from throttle linkage.
  6.  
  7. Disconnect throttle cable from throttle linkage (A/T).
  8.  
  9. Remove air cleaner cap, air flow meter and air cleaner hose:
    1. Disconnect the air flow meter connector.
    2.  
    3. Disconnect the coil cord clamp.
    4.  
    5. Disconnect the air hoses.
    6.  
    7. Loosen the air cleaner hose clamp bolt.
    8.  
    9. Disconnect the air cleaner cap clips.
    10.  
    11. Remove the air cleaner cap and air flow meter together with the air cleaner hose.
    12.  

  10.  
  11. Using a 5 mm hexagon wrench, remove the two nuts and V-bank cover.

    Click image to see an enlarged view

    Fig. Injector related components-1992-93 models

  12.  
  13. Remove emission control valve set:
    1. Disconnect the EGR gas temp. sensor connector clamp from the emission control valve set.
    2.  
    3. Disconnect the two vacuum hoses of he fuel pressure control VSV.
    4.  
    5. Disconnect the two vacuum hoses of the IACV VSV.
    6.  
    7. Disconnect the two VSV connectors.
    8.  
    9. Remove the two bolts and emission control valve set.
    10.  

  14.  
  15. Disconnect the hoses:

    Brake booster vacuum hose
     
    PS air hose
     
    PCV hose
     
    IACV vacuum hose
     

  16.  
  17. Remove the nut and disconnect the two ground straps.
  18.  
  19. Disconnect cold start injector connector
  20.  
  21. Disconnect cold start injector pipe (No. 2 fuel pipe):
    1. Put a suitable container or shop towel under the injector pipe.
    2.  
    3. Slowly loosen the union bolt, remove the union bolt and two gaskets, and disconnect the injector pipe.

      Click image to see an enlarged view

      Fig. Disconnect cold start injector pipe (No. 2 fuel pipe)

    4.  

  22.  
  23. Remove No. 1 engine hanger and air intake chamber stay:
    1. Remove the two bolts and No. 1 engine hanger.
    2.  
    3. Remove the two bolts and air intake chamber stay.
    4.  

  24.  
  25. Loosen the union nut, remove the two bolts and EGR pipe.
  26.  
  27. Remove the bolt and disconnect the hydraulic motor pressure pipe from the air intake chamber.
  28.  
  29. Remove the air intake chamber:
    1. Disconnect the three emission control vacuum hoses.
    2.  
    3. Disconnect the two water by-pass hoses.
    4.  
    5. Disconnect the EGR gas temperature sensor connector (Calif. only).
    6.  
    7. Disconnect the throttle position sensor connector.
    8.  
    9. Disconnect the ISC valve connector.
    10.  
    11. Disconnect the ISC valve air hose.
    12.  
    13. Disconnect the power steering air hose.
    14.  
    15. Using 8 mm hexagon wrench, remove the two bolts, nuts, air intake chamber and gasket.
    16.  

  30.  
  31. Disconnect fuel inlet and return hoses:
    1. Disconnect the fuel return hoses from the No. 1 fuel pipe.
    2.  
    3. Disconnect the fuel inlet hose from the fuel filter.
    4.  

  32.  
  33. Disconnect the injector connectors.
  34.  
  35. Remove the No. 2 fuel pipe:
    1. Disconnect the vacuum hose.
    2.  
    3. Remove the two union bolts, four gaskets and No. 2 fuel pipe.
    4.  

  36.  
  37. Remove the left-hand delivery pipes and injectors:
    1. Disconnect the fuel hose from the No.1 fuel pipe.
    2.  
    3. Remove two bolts and left-hand delivery pipe together with the three injectors. Be careful not to drop the injectors.
    4.  
    5. Pull out the three injectors from the left-hand delivery pipe.
    6.  
    7. Remove the two spacers from the intake manifold.
    8.  

  38.  
  39. Remove the air pipe with hoses:
    1. Disconnect the two air hoses.
    2.  
    3. Remove the bolts and air pipe with hoses.
    4.  

  40.  
  41. Remove the right-hand delivery pipe and injectors:
    1. Remove three bolts and right-hand delivery pipe together with the three injectors. Be careful not to drop the injectors.
    2.  
    3. Pull out the three injectors from the right-hand delivery pipe.
    4.  
    5. Remove the two spacers from the intake manifold.

      Click image to see an enlarged view

      Fig. Remove the right-hand delivery pipe and injectors

    6.  

  42.  

To install:

  1. Install the injectors to the delivery pipes:
    1. Install two new grommets to the injector.
    2.  
    3. Apply a light coat of gasoline to two new O-rings and install them to the injector.

      Click image to see an enlarged view

      Fig. Injector O-ring installation

    4.  
    5. When turning the injector left and right, install it to the delivery pipes. Install the six injectors.

      Click image to see an enlarged view

      Fig. Correct injector installation to fuel rail

    6.  

  2.  
  3. Install the right-hand delivery pipe and injectors:
    1. Place the two spacers in position on the intake manifold.
    2.  
    3. Clean the injector holes before installing the injectors into the intake manifold.
    4.  
    5. Place the three injectors together with the right-hand delivery pipe and No. 1 fuel pipe in position on the intake manifold.
    6.  
    7. Check that the injectors rotate smoothly.
      NOTE
      If the injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

    8.  
    9. Position the injector connector upward.

      Click image to see an enlarged view

      Fig. Injector connector positioning

    10.  
    11. Install and tighten the three bolts to 9 ft. lbs. (13 Nm).
    12.  

  4.  
  5. Install the air pipe with hoses:
    1. Install the air pipe and tighten the two bolts to 74 inch lbs. (8 Nm).
    2.  
    3. Connect the two air hoses.
    4.  

  6.  
  7. Install the left-hand delivery pipe and injectors:
    1. Place the two spacers in position on the intake manifold.
    2.  
    3. Clean the injector holes before installing the injectors into the intake manifold.
    4.  
    5. Place the three injectors together with the left-hand delivery pipe in position on the intake manifold.
    6.  
    7. Check that the injectors rotate smoothly.
      NOTE
      If the injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

    8.  
    9. Position the injector connector upward.
    10.  
    11. Install and tighten the two bolts to 9 ft. lbs. (13 Nm).
    12.  
    13. Connect the fuel hose to the No. 1 fuel pipe.
    14.  

  8.  
  9. Install the No. 2 fuel pipe:
    1. Install the No. 2 fuel pipe with four new gaskets and tighten the two union bolts to 25 ft. lbs. (34 Nm).
    2.  
    3. Connect the IACV vacuum hose.
    4.  

  10.  
  11. Connect the injector connectors.
  12.  
  13. Connect the fuel inlet and return hoses:
    1. Connect the inlet hose to the fuel filter with two new gaskets and tighten the union bolt to 22 ft. lbs. (29 Nm).
    2.  
    3. Connect the return hose to the No. 1 fuel pipe.
    4.  

  14.  
  15. Using 8 mm hexagon wrench, install a new gasket and the air intake number with the two bolts and nuts. Tighten to 32 ft. lbs. (43 Nm).
    1. Connect the throttle position sensor connector.
    2.  
    3. Connect the ISC valve connector.
    4.  
    5. Connect the ISC valve air hose.
    6.  
    7. Connect PS air hose.
    8.  
    9. Connect the EGR gas temperature sensor connector (Calif. only).
    10.  
    11. Connect the following hoses:

      Water by-pass hose to throttle body
       
      Water by-pass hose to EGR cooler
       
      Vacuum hose (from EGR valve) to BVSV (for EGR)
       
      Vacuum hose (from EGR vacuum modulator) to BVSV (for EGR)
       
      Vacuum hose (from throttle body) to BVSV (for EVAP)
       

    12.  

  16.  
  17. Connect the hydraulic pressure pipe to the air intake chamber with the bolt.
  18.  
  19. Install a new gasket, sleeve ball and the EGR pipe with the two bolts and union nut. Tighten the bolt to 13 ft. lbs. (18 Nm) and the union nut to 58 ft. lbs. (78 Nm).
  20.  
  21. Install the No. 1 engine hanger and air intake chamber stay:
    1. Install the air intake chamber stay and tighten the two bolts to 29 ft. lbs. (39 Nm).
    2.  
    3. Install the No. 1 engine hanger and tighten the two bolts to 29 ft. lbs. (39 Nm).
    4.  

  22.  
  23. Connect the cold start injector pipe (No. 2 fuel pipe) with two new gaskets and tighten the union bolt to 11 ft. lbs. (15 Nm).
  24.  
  25. Connect the cold start injector connector
  26.  
  27. Connect the two ground straps and tighten the nut to 9 ft. lbs. (13 Nm).
  28.  
  29. Connect the hoses:

    Brake booster vacuum hose
     
    Power steering air hose
     
    PCV hose
     
    IACV vacuum hose
     

  30.  
  31. Install the emission control valve set:
    1. Install the emission control valve set with the two bolts.
    2.  
    3. Connect the two VSV connectors.
    4.  
    5. Connect the two vacuum hoses of the IACV VSV.
    6.  
    7. Connect the two vacuum hoses of the fuel pressure control VSV.
    8.  
    9. Connect the EGR gas temp. sensor connector clamp to the emission control valve set.
    10.  

  32.  
  33. Using a 5 mm hexagon wrench, install the V-bank cover with the two nuts.
  34.  
  35. Connect the air cleaner hose, and install the air cleaner cap and air flow meter with the four clips.
  36.  
  37. Tighten the air cleaner hose clamp bolt.
  38.  
  39. Connect the air hoses.
  40.  
  41. Connect the coil cord clamp.
  42.  
  43. Connect the air flow meter connector.
  44.  
  45. Connect and adjust throttle cable (A/T).
  46.  
  47. Connect and adjust the accelerator cable.
  48.  
  49. Fill with engine coolant
  50.  
  51. Connect cable to negative terminal of battery
  52.  

Specific to:

Lexus ES300 1994-1997

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Relieve the fuel pressure from the fuel lines.
    CAUTION
    Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Remove the air cleaner hose from the engine compartment.
  6.  
  7. Remove the V-bank cover from the engine.
  8.  
  9. Remove the air cleaner chamber assembly as follows:
    1. Drain the engine coolant from the vehicle.
    2.  
    3. Disconnect the accelerator cable.
    4.  
    5. Disconnect the A/T throttle cable.
    6.  
    7. Disconnect the TPS connector.
    8.  
    9. Disconnect the IAC valve connector.
    10.  
    11. Disconnect the EGR gas temperature sensor connector.
    12.  
    13. Disconnect the A/C idle up valve connector.
    14.  
    15. Disconnect the VSV connector for the ACIS.
    16.  
    17. Disconnect the VSV connector for the fuel pressure control.
    18.  
    19. Disconnect the VSV for the EVAP.
    20.  
    21. Disconnect the VSV connector for the EGR.
    22.  
    23. Disconnect the DLC1 from the bracket on the intake air control valve.
    24.  
    25. Remove the power steering pressure tube from the No. 1 engine hanger by removing the two bolts.
    26.  
    27. Disconnect the brake booster vacuum hose from the intake air control valve for the ACIS.
    28.  
    29. Disconnect the PCV hose from the PCV valve on the right hand cylinder head.
    30.  
    31. Disconnect the ground strap and cable from the air intake air control valve from the ACIS.
    32.  
    33. Disconnect the ground cable from the air intake chamber.
    34.  
    35. Disconnect the vacuum hose clamp from fuel pipe.
    36.  
    37. Disconnect the two bypass hoses from the throttle body.
    38.  
    39. Disconnect the air assist hose from the throttle body.
    40.  
    41. Disconnect the two power steering air hoses to the air intake chamber.
    42.  
    43. Remove the EVAP hose from the pipe on emission control valve set.
    44.  
    45. Disconnect the two vacuum hoses from the pipes on the cylinder head rear plate.
    46.  
    47. Disconnect the vacuum sensing hose from the fuel pressure regulator.
    48.  
    49. Disconnect the engine wire clamp from emission control valve set.
    50.  
    51. Remove the two bolts and the No. 1 engine hanger.
    52.  
    53. Remove the two bolts and the air intake chamber stay.
    54.  
    55. Remove the No. 2 EGR pipe and two gaskets by removing the four nuts.
    56.  
    57. Disconnect the hose from the VSV fro the EVAP.
    58.  
    59. Using an 8mm hexagon wrench, remove the two bolts. Remove the two nuts, the air intake chamber assembly and the gasket.

      Click image to see an enlarged view

      Fig. Injector related components-1996 models shown, other models similar

    60.  

  10.  
  11. Disconnect the fuel injector connectors.
  12.  
  13. Remove the air assist hoses and pipe.
  14.  
  15. Disconnect the fuel return hose from the No. 1 fuel pipe.
  16.  
  17. Disconnect the fuel inlet hose from the fuel filter. Catch any fuel leaking from the filter in a shop rag. Dispose of the rag properly.
  18.  
  19. Remove the delivery pipes and injectors from the engine as follows:
    1. Loosen the two union bolts holding the No. 2 fuel pipe to the delivery pipes.
    2.  
    3. Disconnect the fuel return hose from the fuel pressure regulator.
    4.  
    5. Remove the union bolt and two gaskets for the right hand delivery pipe.
    6.  
    7. Remove the two bolts to the left hand delivery pipe and then remove the left hand delivery pipe, three injectors and the No. 2 fuel pipe as an assembly.
    8.  
    9. Remove the union bolt and two gaskets from the left hand delivery pipe. Disconnect the No. 2 fuel pipe from the left hand delivery pipe.
    10.  
    11. Remove the right hand delivery pipe by removing the three bolts. Remove the delivery pipe, injectors and the fuel inlet hose as an assembly.
    12.  
    13. Remove the four spacers from the intake manifold.
    14.  
    15. Pull out the six injectors from the delivery pipes.
    16.  
    17. Remove the two O-rings and two grommets from each injector.
    18.  

  20.  

To install:

  1. Install the injectors as follows:
    1. Install two new grommets to each injector.
    2.  
    3. Apply a light coat of spindle oil or gasoline to the two O-rings and install them to each injector.
    4.  
    5. Install the injector into the delivery pipe by turning the injector back and forth. Install all the injectors into the delivery pipes. Make sure to position the injector electrical connector outward.
    6.  
    7. Place the four spacers in position on the intake manifold.
    8.  
    9. Place the right hand delivery pipe and the No. 1 fuel pipe together with the three injectors in position on the intake manifold.
    10.  
    11. Temporarily install the two bolts holding the right hand delivery pipe to the intake manifold.
    12.  
    13. Temporarily install the bolt holding the No. 1 fuel pipe to the intake manifold.
    14.  
    15. Place the left hand delivery pipe and the No. 2 fuel pipe together with the three injectors in position.
    16.  
    17. Connect the fuel return hose to the fuel pressure regulator.
    18.  
    19. Temporarily install the two bolts holding the left hand delivery pipe to the intake manifold.
    20.  
    21. Temporarily install the No. 2 fuel pipe to the left hand delivery pipe with the union bolts and two new gaskets.
    22.  
    23. Check that the injectors rotate smoothly. If the injectors do not rotate smoothly, the probable cause is incorrect installation of the O-rings. Replace the O-rings.
    24.  
    25. Tighten the four bolts holding the delivery pipes to the intake manifold. Torque the bolts to 7 ft. lbs. (10 Nm).
    26.  
    27. Tighten the bolt holding the No. 1 fuel pipe to the intake manifold. Torque the bolt to 14 ft. lbs. (20 Nm).
    28.  
    29. Tighten the two union bolts holding the No. 2 fuel pipe to the delivery pipes. Torque the bolts to 24 ft. lbs. (33 Nm).
    30.  

  2.  
  3. Connect the fuel inlet hose to the fuel filter by installing the union bolt. Use two new gaskets when installing the union bolt.
  4.  
  5. Connect the fuel return hose to the No. 1 fuel pipe. When routing the fuel return hose, pass the hose under the heater hoses.
  6.  
  7. Connect the air assist hoses to the intake manifold and then install the air assist pipe to the bracket on the No. 1 fuel pipe.
  8.  
  9. Connect the injector connectors.
  10.  
  11. Install the air intake chamber assembly as follows:
    1. Using an 8mm hexagon wrench, install the air intake chamber with a new gasket. Install the two bolts and two nuts. Uniformly tighten the bolts and nuts in several passes and then torque the bolts and nuts to 32 ft. lbs. (43 Nm).
    2.  
    3. Connect the hose to the VSV for the EVAP system.
    4.  
    5. Install the two new gaskets and No. 2 EGR pipe with the four nuts. Torque the nuts to 9 ft. lbs. (12 Nm).
    6.  
    7. Install the No. 1 engine hanger with the two bolts. Torque the bolts to 19 ft. lbs. (39 Nm).
    8.  
    9. Install the air intake chamber stay with the two bolts. Torque the bolts to 14 ft. lbs. (20 Nm).
    10.  
    11. Connect the brake booster vacuum hose to the intake air control valve for the ACIS.
    12.  
    13. Connect the PCV hose to the PCV valve on the right hand cylinder head.
    14.  
    15. Connect the ground strap and cable to the intake air control valve for the ACIS.
    16.  
    17. Connect the ground cable and strap with the nut. Torque the nut to 10 ft. lbs. (14.5 Nm).
    18.  
    19. Connect the ground cable to air intake chamber.
    20.  
    21. Connect the vacuum hose clamp to fuel pipe.
    22.  
    23. Connect the two water bypass hoses to the throttle body.
    24.  
    25. Connect the air assist hose to the throttle body.
    26.  
    27. Connect the two power steering air hoses to the air intake chamber.
    28.  
    29. Connect the EVAP hose to the pipe on the emission control valve set.
    30.  
    31. Connect the two vacuum hoses to the pipes on the cylinder head rear plate.
    32.  
    33. Connect the vacuum sensing hose to the fuel pressure regulator.
    34.  
    35. Connect the engine wire clamp to the emission control valve set.
    36.  

  12.  
  13. Install the power steering pressure tube with the two nuts.
    1. Connect the TPS sensor connector.
    2.  
    3. Connect the IAC valve connector.
    4.  
    5. Connect the EGR gas temperature sensor connector.
    6.  
    7. Connect the A/C idle up valve connector.
    8.  
    9. Connect the VSV connector for the ACIS.
    10.  
    11. Connect the VSV connector for the fuel pressure control.
    12.  
    13. For California vehicles, install the VSV connector for the EVAP.
    14.  
    15. Connect the VSV connector for the EGR.
    16.  
    17. Connect the DLC1 to the bracket on the intake air control valve.
    18.  
    19. Connect the accelerator cable.
    20.  
    21. Connect the A/T throttle cable.
    22.  

  14.  
  15. Install the V-bank cover.
  16.  
  17. Install the air cleaner hose to the engine.
  18.  
  19. Fill the engine coolant.
  20.  
  21. Connect the negative battery cable to the battery and start the engine.
  22.  
  23. Check the engine coolant level and check for leaks.
  24.  

 
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