Lexus Car ES, IS, LS 1998-06

Direct Injection System (DFI)

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Fuel Pressure Pulsation Damper



Removal & Installation
4gr-Fse & 2gr-Fse Engines


Click image to see an enlarged view

Fig. Fuel pressure pulsation damper-2.5L (4GR-FSE) and 3.5L (2GR-FSE) engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  6.  
  7. Remove the V-bank cover sub-assembly.
  8.  
  9. Remove the fuel pressure pulsation damper and 2 gaskets, and disconnect the fuel tube from the fuel pump.
  10.  

To install:

  1. Install 2 new gaskets, the fuel tube and pulsation damper to the fuel pump. Tighten the fuel pressure pulsation damper to 30 ft. lbs. (40 Nm).
  2.  
  3. Install the V-bank cover.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Perform system initialization procedure.
  8.  

Fuel Pump



Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do NOT lift the fuel pump assembly up using the wiring harness.



    Rear seat cushion
     
    Floor service hole cover
     
    Fuel pump electrical connector
     
    Retaining clip and fuel tank return vent tube
     
    Retaining clip and fuel tank main tube
     
    8 screws and lift out the pump/bracket assembly with gasket
     



    Fuel tube from fuel pump
     

  8.  
  9. Separate the fuel pump assembly from the fuel pump/sending unit
  10.  
  11. Separate the fuel filter from the fuel pump/sending unit
  12.  

To install:

  1. Install or connect the following:

    Filter and rubber cushion on the pump/sending unit
     
    New pump on the pump/sending unit
     
    Fuel tube to the fuel pump
     
    Pump/sending unit, using a new gasket and tighten the 8 screws to 53 inch lbs. (6 Nm)
     
    Fuel tank main tube and retaining clip
     
    Fuel tank return vent tube and retaining clip
     
    Fuel pump electrical connector
     
    Floor service hole cover
     
    Rear seat cushion
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

Fuel Rail & Injectors



Removal & Installation
4gr-Fse & 2gr-Fse Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Coolant
     
    Cool air intake duct seal
     
    Left and right engine room side covers
     
    V-bank cover
     
    Left and right front upper fender protectors
     
    Left and right roof drip side finish mouldings using a moulding removal tool
     
    Front wiper arm head cap
     
    Left and right windshield wiper arm and blade assemblies
     
    Cowl top ventilator louver assembly
     
    No. 2 ventilation hose
     
    Air cleaner cap with air cleaner hose
     
    Throttle body assembly
     
    Cold start injector
     
    Intake air surge tank
     
    Intake manifold
     
    Water hose joint
     
    Fuel pressure pulsation damper
     
    No. 3 fuel hose from the No. 1 fuel pipe and remove fuel pipe
     
    No. 2 and 3 fuel pipes
     
    No. 1 and 2 fuel delivery pipes
     
    Fuel injectors, O-rings and seals
     

  6.  

To install:

  1. Install or connect the following:

    2 new seals to each injector
     

  2.  
  3. Install the fuel injectors as follows:
    1. Install a new O-ring, new backup rings (No. 1, No. 2, No. 3) and new E-ring to the fuel injector.
      WARNING
      Check that there is no foreign matter or damaged areas in the injector's O-ring groove. Check that the installation direction of the No. 1 and No. 2 backup ring are correct. Make sure 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. After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

    2.  
    3. Install the injector nozzle holder clamp.
    4.  
    5. Apply gasoline to the O-ring. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.
      WARNING
      Make sure there is no gap between the delivery pipe and clamp. Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe. Insert the injector straight into the delivery pipe without tilting it.



      No. 1 and 2 fuel delivery pipes. Torque the fasteners to 15 ft. lbs. (21 Nm).
       
      No. 2 and 3 fuel pipes and new O-rings. Torque No. 3 fuel pipe fastener to 7 ft. lbs. (10 Nm).
       
      No. 1 fuel pipe. Torque fasteners to 7 ft. lbs. (10 Nm).
       
      Fuel pressure pulsation damper and new gasket. Torque to 28 ft. lbs. (40 Nm).
       
      Water hose joint. Torque fasteners to 7 ft. lbs. (10 Nm).
       
      Intake manifold
       
      Intake air surge tank
       
      Cold start injector. Torque the bolts to 7 ft. lbs. (10 Nm).
       
      New gasket and throttle body assembly. Torque the 4 bolts to 7 ft. lbs. (10 Nm)
       
      Air cleaner cap with air cleaner hose
       
      No. 2 ventilation hose
       
      Cowl top ventilator louver assembly
       
      Left and right windshield wiper arm and blade assemblies
       
      Front wiper arm head cap
       
      Left and right roof drip side finish mouldings
       
      Left and right front upper fender protectors
       
      V-bank cover
       
      Left and right engine room side covers
       
      Cool air intake duct seal
       
      Negative battery cable
       

    6.  

  4.  
  5. Refill the cooling system. Start the engine and check for coolant and fuel leaks and proper operation.
  6.  
  7. Check the function of the throttle body unit
  8.  
  9. System initialization
  10.  

Throttle Body



Removal & Installation
4gr-Fse & 2gr-Fse Engines


Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components.-2.5L (4GR-FSE) and 3.5L (2GR-FSE) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  4.  
  5. Remove the cool air intake duct seal.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the right engine room side cover.
  10.  
  11. Remove the V-bank cover.
  12.  
  13. Disconnect the No. 2 ventilation hose from the cylinder head.
  14.  
  15. Remove the air cleaner cap with air cleaner hose as follows:


    1. Disconnect the MAF meter connector.
    2.  
    3. Disconnect the clamp from the air cleaner.
    4.  
    5. Disconnect the VSV hose.
    6.  
    7. Disconnect the 4 clamps.
    8.  
    9. Remove the hose clamp and air cleaner cap with air cleaner hose.
    10.  

  16.  
  17. Remove the throttle body assembly as follows:


    1. Disconnect the throttle motor connector.
    2.  
    3. Remove the 4 bolts and disconnect the throttle body from the intake air surge tank.
    4.  
    5. Disconnect the 2 water bypass hoses from the throttle body.
    6.  
    7. Remove the throttle body and gasket.
    8.  

  18.  

To install:

  1. Install the throttle body assembly as follows:


    1. Install a new gasket to the intake air surge tank. Align the protrusion of the gasket on the intake air surge tank.
    2.  
    3. Connect the 2 water by-pass hoses to the throttle body.
    4.  
    5. Install the throttle body with the 4 bolts. Tighten the 4 bolts to 7 ft. lbs. (10 Nm).
    6.  
    7. Connect the throttle motor connector.
    8.  

  2.  
  3. Install air cleaner cap with air cleaner hose as follows:


    1. Install the air cleaner cap with air cleaner hose assembly with the 4 clamps and hose clamp.
    2.  
    3. Install the VSV hose to the air cleaner hose.
    4.  
    5. Connect the MAF meter connector and clamp to the air cleaner.
    6.  

  4.  
  5. Connect the No. 2 ventilation hose to the cylinder head cover with the clamp.
  6.  
  7. Refill the engine cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Check the cooling system for leaks.
  12.  
  13. Inspect the throttle control motor for operating sound as follows:


    1. Turn the ignition switch ON.