Lexus Car ES, IS, LS 1998-06

Fuel Injectors

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Removal & Installation



1MZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    3 cap nuts, using a 5mm hexagon wrench. Loosen the V-bank cover fastener counterclockwise.
     
    V-bank cover
     
    Air cleaner hose with resonator
     
    air intake chamber assembly
     
    Injector connectors
     
    Air assist hoses and pipe
     
    No. 1 fuel pipe and remove the fuel hose clamp
     
    No. 1 fuel pipe (fuel tube connector) from the fuel filter outlet
     
    5 bolts and delivery pipes together with the 6 injectors and No. 1 fuel pipe.
     
    4 spacers from the intake manifold
     
    6 injectors form he delivery pipes
     
    2 O-rings and 2 grommets from each injector
     

  4.  

To install:

  1. Install or connect the following:

    New insulator and grommet to each injector
     
    New O-rings, coated with gasoline, to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning it clockwise, into the delivery pipe
     

  2.  


NOTE
Position the injector connector outward.



The 4 spacers in position on the intake manifold
 
A light coat of gasoline on the place where the intake manifold touches an O-ring
 
The delivery pipe and fuel pipe together with the 6 injectors in position on the intake manifold. Position the injector connector outward.
 
4 bolts holding the delivery pipes to the intake manifold, temporarily
 
Bolt holding the No. 1 fuel pipe to the intake manifold, temporarily
 


NOTE
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.



4 bolts holding the delivery pipes to the intake manifold. Torque to 14 ft. lbs. (19.5 Nm)
 
No. 1 fuel pipe (fuel tube connector) to the fuel filter
 
Fuel hose clamp to the fuel filter with a -click- sound. After installing the clamp, check that the clamp is fixed by pulling up the clamp.
 
Air assist hoses
 
Injector connectors
 
Air intake chamber assembly
 
Air cleaner hose with resonator
 
V-bank cover, using a 5mm hexagon wrench with the 3 cap nuts
 
Press down the V-bank cover.
 

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    3 cap nuts, using a 5mm hexagon wrench. Loosen the V-bank cover fastener counterclockwise.
     
    V-Bank cover
     
    Air cleaner hose with resonator
     
    air intake chamber assembly
     
    Injector connectors
     
    Air assist hoses and pipe
     
    No. 1 fuel pipe and remove the fuel hose clamp
     
    No. 1 fuel pipe (fuel tube connector) from the fuel filter outlet
     
    5 bolts and delivery pipes together with the 6 injectors and No. 1 fuel pipe.
     
    4 spacers from the intake manifold
     
    6 injectors form he delivery pipes.
     
    2 O-rings and 2 grommets from each injector
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    Position the injector connector outward.


    NOTE
    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.



    New insulator and grommet to each injector
     
    New O-rings, coated with gasoline, to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning it clockwise, into the delivery pipe
     



    The 4 spacers in position on the intake manifold
     
    A light coat of gasoline on the place where the intake manifold touches an O-ring
     
    The delivery pipe and fuel pipe together with the 6 injectors in position on the intake manifold. Position the injector connector outward.
     
    Temporarily, the 4 bolts holding the delivery pipes to the intake manifold
     
    Temporarily install the bolt holding the No. 1 fuel pipe to the intake manifold.
     



    4 bolts holding the delivery pipes to the intake manifold. Torque to 14 ft. lbs. (19.5 Nm)
     
    No. 1 fuel pipe (fuel tube connector) to the fuel filter
     
    Fuel hose clamp to the fuel filter with a -click- sound. After installing the clamp, check that the clamp is fixed by pulling up the clamp.
     
    Air assist hoses
     
    Injector connectors
     
    Air intake chamber assembly
     
    Air cleaner hose with resonator
     
    V-bank cover, using a 5mm hexagon wrench with the 3 cap nuts.
     
    Press down the V-bank cover.
     

  2.  

1UZ-FE & 3UZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    V-bank cover
     
    Intake air connector
     
    Accelerator cable
     
    Fuel pressure pulsation dampers.
     
    VVT sensor connectors
     
    Vacuum Switching Valve (VSV) for Evaporative Emissions (EVAP)
     
    2 nuts and accelerator cable bracket
     
    2 nuts and accelerator cable bracket
     
    3 V-bank cover brackets
     
    VSV connector for Acoustic Control Induction System (ACIS) from the No. 1 V-bank cover bracket
     
    4 bolts and 3 V-bank cover brackets
     
    Engine wire from the delivery pipe
     
    2 wire clamps from the wire clamp bracket on the right-hand deliver pipe
     
    8 injector connectors
     
    4 nuts holding the delivery pipe to the intake manifold
     
    2 delivery pipes and 8 injectors assembly and 4 spacers
     
    2 O-rings, grommet and insulator from each injector
     

  4.  

To install:

  1. Install or connect the following:

    A new insulator and grommet to each injector
     
    A light coat of gasoline to new O-rings and install them to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning the clockwise and counterclockwise, into the delivery pipe
     

  2.  


NOTE
Position the injector connector outward.



The 4 spacers in position on the intake manifold
 
A light coat of gasoline on the place where an intake manifold touches an O-ring
 
The delivery pipes in position on the intake manifold
 
Temporarily, the 3 bolts holding the delivery pipe to the intake manifold
 


NOTE
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.

  1. Tighten the 3 bolts holding the delivery pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm).
  2.  
  3. Install or connect the following:

    Engine wire protector with the 3 nuts
     
    Injector connectors
     
    Remaining components
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    V-bank cover
     
    Intake air connector
     
    Accelerator cable.
     
    Fuel pressure pulsation dampers.
     
    VVT sensor connectors
     
    Vacuum Switching Valve (VSV) for Evaporative Emissions (EVAP)
     
    2 nuts and accelerator cable bracket
     
    2 nuts and accelerator cable bracket
     
    3 V-bank cover brackets
     
    VSV connector for Acoustic Control Induction System (ACIS) from the No. 1 V-bank cover bracket.
     
    4 bolts and 3 V-bank cover brackets
     
    Engine wire from the delivery pipe
     
    2 wire clamps from the wire clamp bracket on the right-hand deliver pipe
     
    8 injector connectors
     
    4 nuts holding the delivery pipe to the intake manifold
     
    2 delivery pipes and 8 injectors assembly and 4 spacers
     
    2 O-rings, grommet and insulator from each injector
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    Position the injector connector outward.


    NOTE
    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.



    A new insulator and grommet to each injector
     
    A light coat of gasoline to new O-rings and install them to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning the clockwise and counterclockwise, into the delivery pipe
     



    The 4 spacers in position on the intake manifold
     
    A light coat of gasoline on the place where an intake manifold touches an O-ring
     
    The delivery pipes in position on the intake manifold
     
    Temporarily, the 3 bolts holding the delivery pipe to the intake manifold
     

  2.  
  3. Tighten the 3 bolts holding the delivery pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm).
  4.  
  5. Install or connect the following:

    Engine wire protector with the 3 nuts.
     
    Injector connectors.
     
    Remaining components
     

  6.  

2.5L & 4.0L Engines


Click image to see an enlarged view

Fig. Fuel injector locations on a 2.5L and 4.0L engines

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Fuel injector connectors
     
    Fuel line
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Cable routing bracket
     
    Fuel supply manifold with injectors attached
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors, using new O-rings
     
    Fuel supply manifold with injectors. Tighten the bolts to 75-125 inch lbs. (8-14 Nm).
     
    Cable routing bracket
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Fuel line
     
    Fuel injector connectors
     
    Air intake tube
     
    Negative battery cable
     

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

2JZ-GE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Air intake chamber
     
    Fuel pressure pulsation damper
     
    Engine wire from intake manifold
     
    Bolt holding the engine wire protector to the body
     
    6 injector connectors
     
    Camshaft Position (CMP) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Vacuum Switching Valve (VSV) connector for Evaporative Emission (EVAP) control
     
    VSV connector for Acoustic Control Induction System (ACIS)
     
    3 nuts holding the engine wire protector to the intake manifold
     

  4.  


NOTE
Be careful not to drop the injectors when removing the delivery pipe.



3 bolts and delivery pipe together with the 6 injectors
 
The injectors from the delivery pipe
 
O-rings, insulator and grommet from each injector
 
3 spacers from the intake manifold
 

To install:

  1. Install or connect the following:

    A new insulator and grommet to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning clockwise and counterclockwise, into the delivery pipe
     

  2.  


NOTE
Position the injector connector outward.



The 3 spacers in position on the intake manifold
 
A light coat of gasoline on the place where an intake manifold touches an O-ring
 
Injectors together with the delivery pipe and 3 bolts in position on the intake manifold. Check that the injectors rotate smoothly. Position the injector connector upward.
 


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

  1. Tighten the 3 bolts holding the delivery pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm).
  2.  
  3. Install or connect the following:

    Engine wire protector with the 3 nuts
     
    6 injector connectors
     

  4.  


NOTE
The No. 1, No. 3 and No. 5 injector connectors are dark gray, and the No. 2, No. 4, and the No. 6 injectors connectors are brown.

  1. Install or connect the following:

    Camshaft position sensor connector
     
    Throttle position sensor connector
     
    VSV connector for EVAP
     
    Bolt holding the engine wire protector to the body
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Be careful not to drop the injectors when removing the delivery pipe.



    Air intake chamber
     
    Fuel pressure pulsation damper
     
    Engine wire from intake manifold
     
    Bolt holding the engine wire protector to the body
     
    6 injector connectors
     
    Camshaft Position (CMP) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Vacuum Switching Valve (VSV) connector for Evaporative Emission (EVAP) control
     
    VSV connector for Acoustic Control Induction System (ACIS)
     
    3 nuts holding the engine wire protector to the intake manifold
     



    3 bolts and delivery pipe together with the 6 injectors
     
    The injectors from the delivery pipe
     
    O-rings, insulator and grommet from each injector
     
    3 spacers from the intake manifold
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    Position the injector connector outward.


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



    A new insulator and grommet to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning clockwise and counterclockwise, into the delivery pipe
     



    The 3 spacers in position on the intake manifold
     
    A light coat of gasoline on the place where an intake manifold touches an O-ring
     
    Injectors together with the delivery pipe and 3 bolts in position on the intake manifold. Check that the injectors rotate smoothly. Position the injector connector upward.
     

  2.  
  3. Tighten the 3 bolts holding the delivery pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm).
  4.  
  5. Install or connect the following:
    NOTE
    The No. 1, No. 3 and No. 5 injector connectors are dark gray, and the No. 2, No. 4, and the No. 6 injectors connectors are brown.



    Engine wire protector with the 3 nuts.
     
    6 injector connectors.
     

  6.  
  7. Install or connect the following:

    Camshaft position sensor connector
     
    Throttle position sensor connector
     
    VSV connector for EVAP
     
    Bolt holding the engine wire protector to the body.
     

  8.  

3MZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Suspension upper center brace
     
    V-bank cover sub assembly
     
    Air cleaner assembly
     
    Emission control valve set
     

  4.  
  5. Remove intake air surge tank
  6.  
  7. Remove or disconnect the following:

    Throttle motor connector
     
    Water by-pass hoses
     
    Union check valve hose
     
    Ventilation hose
     
    Pressure feed hose
     
    Engine hangers
     
    Surge tank stays
     
    Bond cable connector
     
    Emission control valve bracket
     
    Intake air surge tank
     


    Click image to see an enlarged view

    Fig. Exploded view of Intake Air Surge tank-3.3L (3MZ-FE) Engine

    Gasket from intake air surge tank
     

  8.  
  9. Remove fuel pipe assembly
  10.  
  11. Remove or disconnect the following:

    Fuel pulsation damper and gasket
     
    Fuel pipe union bolt and 2 gaskets
     
    Bolt and separate the fuel pipe
     

  12.  
  13. Remove the fuel injector assembly
  14.  
  15. Remove or disconnect the following:

    6 fuel injector connectors
     
    4 bolts, then remove the fuel injector delivery pipes
     

  16.  


WARNING
Be careful not to drop the fuel injectors when removing the fuel delivery pipes.



4 delivery pipe spacers from intake manifold
 
6 insulators from the intake manifold
 
fuel injector from the fuel delivery pipes.
 



Click image to see an enlarged view

Fig. Exploded view of fuel injector delivery pipe and injectors-3.3L (3MZ-FE) Engine

To install:

  1. Install new fuel injector assembly
  2.  
  3. Install or connect the following

    A new insulator and grommet to each injector
     
    A light coat of gasoline to new O-rings and install them to each injector
     
    A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector
     
    Injector, while turning the clockwise and counterclockwise, into the delivery pipe
     
    The 6 insulators and 4 spacers in position on the intake manifold
     
    A light coat of gasoline on the place where an intake manifold touches an O-ring
     
    The delivery pipes in position on the intake manifold
     
    Temporarily, the 4 bolts holding the delivery pipe to the intake manifold
     

  4.  


NOTE
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.



4 bolts. Tighten bolts uniformly. Torque to: 7 ft. lbs. (10 Nm)
 
6 fuel injector connectors
 

  1. Install fuel pipe assembly
  2.  
  3. Install or connect the following

    2 gaskets and fuel pipe union bolt
     
    2 gaskets and fuel pressure pulsation damper
     
    Fuel pipe with bolt
     

  4.  
  5. Install intake air surge tank
  6.  
  7. Install or connect the following

    New gaskets to intake air surge tank
     
    Intake air surge tank and emission control valve bracket. Torque: 21 ft. lbs. (28 Nm)
     
    4 bolts. Torque: 21 ft. lbs. (28 Nm)
     
    2 bolts on surge tank stay. Torque: 21 ft. lbs. (28 Nm)
     
    Engine hangers
     
    Pressure feed tube
     

  8.  
  9. Remaining components in reverse order of removal procedure
  10.  
  11. Install engine coolant and check for leaks
  12.  
  13. Perform system initialization
  14.  

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Alternator wiring connectors
     
    Fuel line
     
    Throttle body vacuum lines and electrical connectors
     
    Fuel injector connectors
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Ignition coils
     
    Fuel supply manifold with injectors attached
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors, using new O-rings
     
    Fuel supply manifold with injectors attached. Tighten the bolts to 20 ft. lbs. (27 Nm).
     
    Ignition coils
     
    IAT sensor connector
     
    MAP sensor connector
     
    Fuel injector connectors
     
    Throttle body vacuum lines and electrical connectors
     
    Fuel line
     
    Alternator wiring connectors
     
    Air intake assembly
     
    Negative battery cable
     

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

 
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