Lexus Car ES, IS, LS 1998-06

Sequential Multi-Port Fuel Injection System (SFI)

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Fuel Pressure Pulsation Damper



Removal & Installation
1mz-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the fuel injector assembly and related components-3.0L (1MZ-FE) engine

  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. Drain engine coolant
  8.  
  9. Remove the V-bank cover.
  10.  
  11. Disconnect the positive battery cable and remove the battery.
  12.  
  13. Remove the air cleaner assembly with hose.
  14.  
  15. Remove the front suspension upper brace center.
  16.  
  17. Remove the intake air surge tank (see intake manifold).
  18.  
  19. Remove the fuel pressure pulsation damper and 2 gaskets.
  20.  

To install:

  1. Install the fuel pressure pulsation damper and 2 new gaskets. Tighten the damper to 24 ft. lbs. (33Nm)
  2.  
  3. Install the intake air surge tank (see intake manifold).
  4.  
  5. Install the front suspension upper brace center and tighten the 4 nuts to 59 ft. lbs. (80 Nm).
  6.  
  7. Install the air cleaner assembly with hose.
  8.  
  9. Install the battery and connect the positive battery cable.
  10.  
  11. Install the V-bank cover.
  12.  
  13. Refill the engine coolant.
  14.  
  15. Connect the negative battery cable.
  16.  

1uz-FE & 3uz-FE Engines


Click image to see an enlarged view

Fig. Fuel pressure pulsation damper-4.0L (1UZ-FE) and 4.3L (3UZ-FE) 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. Disconnect the accelerator cable.
  10.  
  11. Disconnect the EVAP hose (from the charcoal canister).
  12.  
  13. Disconnect the EVAP hose.
  14.  
  15. Disconnect the brake booster vacuum hose.
  16.  
  17. Disconnect the 2 EVAP hoses.
  18.  
  19. Disconnect the PCV hose.
  20.  
  21. Disconnect the VSV connector for EVAP.
  22.  
  23. Disconnect the noise filter connector.
  24.  
  25. Remove the 3 bolts, and disconnect the engine wire protector and wire clamp bracket from the intake manifold.
  26.  
  27. Remove the 2 pulsation dampers and 4 gaskets.
  28.  

To install:

  1. Install 4 new gaskets, and the fuel pressure pulsation dampers. Tighten each fuel pressure pulsation damper to 29 ft. lbs. (39 Nm).
  2.  
  3. Connect the engine wire with cover and wire clamp bracket with 3 bolts to intake manifold.
  4.  
  5. Connect the EVAP hose (from the charcoal canister).
  6.  
  7. Connect the EVAP hose.
  8.  
  9. Connect the brake booster vacuum hose.
  10.  
  11. Connect the 2 EVAP hoses.
  12.  
  13. Connect the PCV hose.
  14.  
  15. Connect the VSV connector for EVAP.
  16.  
  17. Connect the noise filter connector.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Check the fuel system for leaks.
  22.  
  23. Connect the accelerator cable.
  24.  
  25. Install the V-bank cover sub-assembly.
  26.  

2jz-Ge Engine


Click image to see an enlarged view

Fig. Fuel pressure pulsation damper-3.0L (2JZ-GE) engine

  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 4 nuts and engine cover.
  8.  
  9. Disconnect the VSV connector for the EVAP.
  10.  
  11. Disconnect the EVAP hose from the EVAP pipe.
  12.  
  13. Disconnect the vacuum hose (from No. 2 vacuum pipe) from the air intake chamber.
  14.  
  15. Remove the fuel pressure pulsation damper as follows:


    1. Remove the nut holding the No. 2 vacuum pipe to the intake manifold.
    2.  
    3. Remove the bolt holding the fuel inlet pipe to the intake manifold.
    4.  
    5. Using SST 09612-24014 (09617-24011), remove the pulsation damper and 2 gaskets. Put a shop towel under the delivery pipe. Slowly loosen the pulsation damper.
    6.  

  16.  

To install:

  1. Install the fuel pressure pulsation damper as follows:


    1. Install the fuel inlet pipe and pulsation damper with 2 new gaskets. Different the gaskets are used for the upper (large side) and lower (small side).
    2.  
    3. Using SST 09612-24014 (09617-24011), tighten the pulsation damper to 24 ft. lbs. (32.5 Nm).
    4.  
    5. Install the bolt holding the fuel inlet pipe to the intake manifold and tighten to 80 inch lbs. (9 Nm).
    6.  
    7. Install the nut holding the No. 2 vacuum pipe to the intake manifold and tighten to 15 ft. lbs. (21 Nm).
    8.  

  2.  
  3. Connect the vacuum hose (from No. 2 vacuum pipe) to the air intake chamber.
  4.  
  5. Connect the EVAP hose to the EVAP pipe.
  6.  
  7. Connect the VSV connector for the EVAP.
  8.  
  9. Install the engine cover with the 4 nuts.
  10.  
  11. Connect the negative battery cable.
  12.  

3mz-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the fuel injector assembly and related components-3.3L (3MZ-FE) engine

  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. Drain engine coolant
  8.  
  9. Remove the front suspension upper brace center.
  10.  
  11. Remove the V-bank cover.
  12.  
  13. Remove the air cleaner cap sub-assembly.
  14.  
  15. Remove the emission control valve set as follows:


    1. Disconnect the 2 VSV connectors.
    2.  
    3. Remove the wire harness clamp.
    4.  
    5. Disconnect the fuel vapor feed hose No. 1.
    6.  
    7. Disconnect the fuel vapor feed hose No. 2.
    8.  
    9. Disconnect the 2 vacuum hoses.
    10.  
    11. Remove the clamp.
    12.  
    13. Remove the 2 nuts, then remove the emission control valve set.
    14.  

  16.  
  17. Remove the intake air surge tank (see intake manifold).
  18.  
  19. Remove the fuel pressure pulsation damper and 2 gaskets.
  20.  

To install:

  1. Install the fuel pressure pulsation damper and 2 new gaskets. Tighten the damper to 24 ft. lbs. (33Nm)
  2.  
  3. Install the intake air surge tank (see intake manifold).
  4.  
  5. Install the emission control valve set as follows:


    1. Place the emission control valve set in position and tighten the 2 nuts to 71 inch lbs. (8 Nm).
    2.  
    3. Install the clamp.
    4.  
    5. Connect the 2 vacuum hoses.
    6.  
    7. Connect the fuel vapor feed hose No. 2.
    8.  
    9. Connect the fuel vapor feed hose No. 1.
    10.  
    11. Install the wire harness clamp.
    12.  
    13. Connect the 2 VSV connectors.
    14.  

  6.  
  7. Install the air cleaner cap sub-assembly.
  8.  
  9. Install the V-bank cover.
  10.  
  11. Install the front suspension upper brace center and tighten the 4 nuts to 59 ft. lbs. (80 Nm).
  12.  
  13. Refill the engine coolant
  14.  
  15. Connect the negative battery cable.
  16.  

Fuel Pressure Regulator



Removal & Installation
  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 fuel pump assembly from the fuel tank.
  8.  
  9. Remove the screw, and pull out the fuel filter.
  10.  
  11. Remove the O-ring from the fuel filter.
  12.  
  13. Remove the screw, and pull out the fuel pressure regulator.
  14.  
  15. Remove the O-ring from the pressure regulator.
  16.  

To install:

  1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
  2.  
  3. Install the fuel pressure regulator and tighten the screw to 17 inch lbs. (2 Nm).
  4.  
  5. Apply a light coat of gasoline to a new O-ring, and install it to the fuel filter.
  6.  
  7. Install the fuel filter and tighten the screw to 17 inch lbs. (2 Nm).
  8.  
  9. Install the fuel pump assembly into the fuel tank.
  10.  
  11. Connect the negative battery cable.
  12.  

  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. Pull out the fuel pressure regulator from the fuel tank fuel filter.
  8.  
  9. Remove the O-ring from the fuel pressure regulator.
  10.  

To install:

  1. Apply a light coat of spindle oil or gasoline to a new O-ring, then install it to the fuel pressure regulator.
  2.  
  3. Push in the fuel pressure regulator to the fuel tank fuel filter.
  4.  
  5. Connect the negative battery cable.
  6.  



Click image to see an enlarged view

Fig. Exploded view of the fuel pump and sender gauge assembly components-IS 300

  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 fuel pump and sender gauge assembly from the fuel tank.
  8.  
  9. Using 2 screwdrivers, disconnect the 4 snap claws from the claw holes and remove the No. 2 fuel suction support. Be careful not to damage the suction supports.
  10.  
  11. Remove the rubber cushion.
  12.  
  13. Disconnect the fuel return jet tube from the clamp of the No.2 fuel suction support.
  14.  
  15. Pull out the fuel pressure regulator from the fuel filter, and remove the fuel pressure regulator and fuel return jet tube assembly.
  16.  
  17. Remove the O-ring from the fuel pressure regulator.
  18.  

To install:

  1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
  2.  
  3. Push in the fuel pressure regulator to the fuel filter.
  4.  
  5. Check that the fuel pressure regulator rotates smoothly. If it does not rotates smoothly, the O-ring may be pinched, so remove the fuel pressure regulator and perform the previous two steps.
  6.  
  7. Connect the fuel return jet tube to the clamp of the No. 2 fuel suction support.
  8.  
  9. Install the rubber cushion to the fuel pump.
  10.  
  11. Push the fuel suction support, and attach the 4 snap claws to the claw holes.
  12.  
  13. Install the fuel pump and sender gauge assembly into the fuel tank.
  14.  
  15. Connect the negative battery cable.
  16.  



Click image to see an enlarged view

Fig. Exploded view of the fuel pump and sender gauge assembly components-LS 400

  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 fuel pump assembly from the fuel tank.
  8.  
  9. Remove the screw, fuel filter and fuel pressure regulator.
  10.  
  11. Remove the O-rings from fuel pressure regulator and fuel filter.
  12.  

To install:

  1. Apply a light coat of gasoline to 2 new O-rings, and install them to the pressure regulator.
  2.  
  3. Insert the pressure regulator into the fuel filter by hand completely.
  4.  
  5. Insert the pressure regulator and fuel filter assembly into the delivery pipe by hand completely.
  6.  
  7. Check that the fuel pressure regulator and fuel filter rotate smoothly. If it does not rotate smoothly. the O-ring may be pinched, so remove the pressure regulator, fuel filter and do the first two installation steps again.
  8.  
  9. Install the screw and tighten to 17 inch lbs. (2 Nm).
  10.  
  11. Install the fuel pump assembly into the fuel tank.
  12.  
  13. Connect the negative battery cable.
  14.  

  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 fuel pump and sender gauge assembly from the fuel tank.
  8.  
  9. Using 2 screwdrivers, disconnect the 3 snap claws from the claw holes and remove the fuel suction support. Be careful not to damage the suction support and fuel filter.
  10.  
  11. Remove the fuel pump cushion rubber.
  12.  
  13. Disconnect the fuel return jet tube from the clamp of the fuel filter.
  14.  
  15. Pull out the fuel pressure regulator from the fuel filter, and remove the fuel pressure regulator and fuel return jet tube.
  16.  
  17. Remove the O-ring from the fuel pressure regulator.
  18.  

To install:

  1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
  2.  
  3. Push in the fuel pressure regulator to the fuel filter.
  4.  
  5. Check that the fuel pressure regulator rotates smoothly. If the regulator does not rotates smoothly, the O-ring may be pinched. Remove the fuel pressure regulator and perform the 2 steps above.
  6.  
  7. Connect the fuel return jet tube to the clamp of the fuel filter.
  8.  
  9. Install the fuel pump cushion rubber.
  10.  
  11. Push the fuel suction support, and attach the 3 snap claws to the claw holes.
  12.  
  13. Install a new gasket to the fuel suction plate.
  14.  
  15. Connect the fuel sub-suction hose to the fuel return jet tube.
  16.  
  17. Attach the fuel pump and sender gauge to the fuel tank.
  18.  
  19. Connect the negative battery cable.
  20.  

Fuel Pump



Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. With the ignition switch in the LOCK position, disconnect the negative battery terminal.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do NOT lift the fuel pump assembly up using the wiring harness.



    Rear seat cushion
     
    Fuel pump connector
     
    Floor service hole cover
     



    Fuel filler cap
     
    Fuel outlet pipe and the return hose from the pump bracket
     
    8 screws and lift out the pump/bracket assembly with gasket
     
    Fuel pump lead wire
     
    Lower end of the pump off the bracket
     
    Fuel hose from the pump and remove the pump
     
    Rubber cushion from the pump
     

  8.  

To install:

  1. Install or connect the following:

    Filter and rubber cushion on the new pump
     
    Pump on the bracket
     
    Fuel hose and the wire connector on the pump
     
    Pump, using a new gasket and tighten the 8 screws to 35 inch lbs. (4 Nm)
     
    Fuel pipe and return hose to the pump and tighten the bolts to 22 ft. lbs. (29 Nm)
     
    Wire
     
    Service cover, and replace the rear seat
     
    Negative battery cable
     

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

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-ES 300

  4.  

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

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Trunk floor mat
     
    Trunk trim cover
     
    Fuel pump electrical connector
     
    Rear seat bottom and seat back
     
    Partition cover
     
    Mounting bolts and remove the fuel pump set plate
     
    3 nuts and disconnect the fuel pump bracket from the tank
     
    Fuel hose from the bracket
     
    Pump, bracket and set plate as an assembly
     

  4.  

To install:

  1. Install or connect the following:

    A new gasket on the set plate
     
    Fuel hose to the pump and bracket
     
    Pump and bracket assembly with the 3 nuts; tighten the nuts to 48 inch lbs. (5 Nm). Install the set plate and tighten the bolts to 26 inch lbs. (3 Nm).
     
    Panel partition
     
    Rear seat cushion and back
     
    Fuel pump electrical connector
     
    Trim panel
     
    Spare tire and the trunk floor mat
     
    Negative battery cable
     

  2.  
  3. Start the engine; check the fuel system for leaks
  4.  

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

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Rear seat bottom and seat back
     
    Fuel pump tube
     
    8 bolts and fuel tank vent tube set plate
     
    Fuel pump and sensor gauge assembly
     
    Fuel suction hose and support
     
    Fuel pump cushion rubber
     
    Fuel pressure w/jet pump regulator assembly
     
    Fuel suction plate w/sender gauge
     
    Fuel pump and filter
     

  4.  

To install:

  1. To install, reverse the removal procedure. Install a new O-ring on the fuel jet pump regulator assembly and a new gasket on the fuel pump/sender gauge assembly. Torque the 8 bolts securing the fuel tank set plate to 52 in. lbs (6 Nm).
  2.  
  3. Inspect fuel pump operation and check for fuel leaks.
  4.  



Click image to see an enlarged view

Fig. Exploded view for fuel pump removal-ES 330

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

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Rear seat bottom and seat back
     
    Rear floor service hole cover
     
    Fuel suction w/pump and gauge tube assembly
     
    8 bolts and fuel tank vent tube set plate
     
    Vapor pressure sensor assembly
     
    Fuel suction hose and support
     
    Fuel pump cushion rubber
     
    Fuel sender gauge assembly
     
    Fuel suction plate w/sender gauge
     
    Fuel pump harness
     
    Fuel pump
     
    Fuel pump filter. Pry out clip and remove from pump
     
    Fuel pressure regulator assembly
     

  4.  

To install:

  1. To install, reverse the removal procedure. Install a new O-ring on the fuel suction w/pump and gauge assembly. Torque the 8 bolts securing the fuel tank set plate to 52 inch lbs. (6.0 Nm).
  2.  
  3. Inspect fuel pump operation and check for fuel leaks.
  4.  

Fuel Rail & Injectors



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 from the 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.
     
    4 bolts holding the delivery pipes to the intake manifold, temporarily
     
    Bolt holding the No. 1 fuel pipe to the intake manifold, temporarily
     



    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 And 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
     
    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.  

2jz-Ge Engine
  1. Before servicing the vehicle, refer to the Precautions 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:
    WARNING
    Be careful not to drop the fuel injectors when removing the fuel delivery pipes.



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

     

  16.  

To install:

  1. Install new fuel injector assembly
  2.  
  3. Install or connect the following
    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 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 bolts. Tighten bolts uniformly. Torque to: 7 ft. lbs. (10 Nm)
     
    6 fuel injector connectors
     

  4.  
  5. Install fuel pipe assembly
  6.  
  7. Install or connect the following

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

  8.  
  9. Install intake air surge tank
  10.  
  11. 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
     

  12.  
  13. Remaining components in reverse order of removal procedure
  14.  
  15. Install engine coolant and check for leaks
  16.  
  17. Perform system initialization
  18.  

Throttle Body



Removal & Installation
1mz-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components.-3.0L (1MZ-FE) 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. Drain the engine coolant.
  6.  
  7. Remove the air cleaner cap with air cleaner hose as follows:


    1. Disconnect the MAF meter connector.
    2.  
    3. Disconnect the VSV connector for canister closed valve (CCV) and the air hose.
    4.  
    5. Disconnect the 4 vacuum hoses and the ventilation hose.
    6.  
    7. Remove the air cleaner cap with the hose.
    8.  

  8.  
  9. Remove the front suspension upper brace center (if equipped).
  10.  
  11. Remove the throttle body assembly as follows:


    1. Disconnect the throttle position sensor connector.
    2.  
    3. Disconnect the throttle control motor connector.
    4.  
    5. Disconnect the 2 water bypass hoses.
    6.  
    7. Remove the 4 bolts, throttle body and gasket.
    8.  

  12.  
  13. Remove the 2 set screws and EFI throttle position sensor.
  14.  

To install:

  1. Install the EFI throttle position sensor as follows:


    1. Check that the throttle valve is under the condition of the opener opening angle (about 6°).
    2.  
    3. Install the sensor to the place where is at 20-30° rotated to the right from the specified installation position.

      Click image to see an enlarged view

      Fig. Turning the throttle position sensor for correct installation.-3.0L (1MZ-FE) engine

    4.  
    5. Gradually turn sensor counterclockwise until it touches the throttle valve shaft, and temporarily tighten the 2 set screws.
    6.  
    7. Connect the throttle position sensor connector.
    8.  
    9. Connect the hand-held tester or OBD II scan tool to the DLC3.
    10.  
    11. Turn the ignition switch ON. After turning the ignition switch ON, do not depress the accelerator pedal.
    12.  
    13. While reading the valve of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA, turn the throttle position sensor slowly to left and right and set the sensor at the center value of the standard value, and then tighten the screws.

      Standard throttle valve opening percentage: 16.0-17.6 %
       
      Torque: 18 inch lbs. (2 Nm)
       

    14.  
    15. Recheck throttle valve opening percentage. If the throttle valve opening percentage is not as specified, repeat the previous step.
    16.  
    17. Perform fully closed throttle valve by hand and check that the valve of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA stays with the standard value.

      Standard throttle valve opening percentage: 10-14 %
       

    18.  
    19. If the throttle valve opening percentage is not as specified, repeat the previous 3 steps.
    20.  
    21. Paint the 2 set screws.
    22.  
    23. Turn the ignition switch OFF.
    24.  
    25. Disconnect the hand-held tester or OBD II scan tool from the DLC3.
    26.  
    27. Disconnect the throttle position sensor connector.
    28.  

  2.  
  3. Install a new gasket and the throttle body assembly. Tighten the 4 bolts to 8 ft. lbs. (11 Nm).
  4.  
  5. Install the air cleaner cap with air cleaner hose assembly.
  6.  
  7. Install the front suspension upper brace center (if equipped). Torque the nuts to 59 ft. lbs. (80 Nm).
  8.  
  9. Refill the engine coolant.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Check the cooling system for leaks.
  14.  
  15. Inspect the throttle control motor for operating sound as follows:


    1. Turn the ignition switch ON.
    2.  
    3. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound.
    4.  

  16.  
  17. Inspect the throttle position sensor as follows:


    1. Connect the hand-held tester or OBD II scan tool to the DLC3.
    2.  
    3. Turn the ignition switch ON.
    4.  
    5. Check that the check engine warning light does not light up.
    6.  
    7. Check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shown the standard value.

      Standard throttle valve opening percentage: 60 % or more
       

    8.  

  18.  

1uz-FE Engine


Click image to see an enlarged view

Fig. Engine compartment air cleaner assembly components.-4.0L (1UZ-FE) engine



Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components (part 1).-4.0L (1UZ-FE) engine



Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components (part 2).-4.0L (1UZ-FE) 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 V-bank cover.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the battery clamp cover and air cleaner inlet.
  10.  
  11. Remove the intake air connector.
  12.  
  13. Disconnect the accelerator cable from the throttle body.
  14.  
  15. Remove the throttle body as follows:


    1. Disconnect the accelerator pedal position sensor connector.
    2.  
    3. Disconnect the throttle position sensor connector.
    4.  
    5. Disconnect the throttle control motor connector.
    6.  
    7. Disconnect the No.1 water bypass hose.
    8.  
    9. Disconnect the No.7 water bypass hose.
    10.  
    11. Disconnect the 2 wire clamps from the throttle body.
    12.  
    13. Remove the 2 bolts, 2 nuts, throttle body and gasket.
    14.  

  16.  

To install:

  1. Install the throttle body as follows:


    1. Install the throttle body assembly with a new gasket, 2 nuts and 2 bolts. Tighten the nuts and bolts to 13 ft. lbs. (18 Nm).
    2.  
    3. Connect the 2 wire clamps to the throttle body.
    4.  
    5. Connect the No.7 water bypass hose.
    6.  
    7. Connect the No.1 water bypass hose.
    8.  
    9. Connect the throttle control motor connector.
    10.  
    11. Connect the throttle position sensor connector.
    12.  
    13. Connect the accelerator pedal position sensor connector.
    14.  

  2.  
  3. Connect the accelerator cable to the throttle body.
  4.  
  5. Install intake air connector.
  6.  
  7. Install battery clamp cover and air cleaner inlet.
  8.  
  9. Refill the engine cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Check the cooling system for leaks.
  14.  
  15. Install V-bank cover.
  16.  

2jz-Ge Engine


Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components (part 1).-3.0L (2JZ-GE) engine



Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components (part 2).-3.0L (2JZ-GE) 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. Drain the engine coolant.
  6.  
  7. Remove the 4 nuts and engine cover.
  8.  
  9. Remove intake air resonator.
  10.  
  11. Remove the throttle body bracket and throttle body assembly as follows:


    1. Disconnect the accelerator cable.
    2.  
    3. Disconnect the throttle position sensor connector.
    4.  
    5. Disconnect the throttle control motor connector.
    6.  
    7. Disconnect the accelerator pedal position sensor connector.
    8.  
    9. Disconnect the engine wire clamp from the clamp bracket of throttle body.
    10.  
    11. Remove the 2 bolts and nut holding the throttle body to the intake air connector.
    12.  
    13. Remove the 4 nuts and throttle body bracket.
    14.  
    15. Slightly slide the throttle body away from the intake air connector.
      NOTE
      When putting up the throttle body, do not hold the motor part.

    16.  
    17. Disconnect the 2 water bypass hoses from the throttle body, and remove the throttle body.
    18.  

  12.  

To install:

  1. Install the throttle body bracket and throttle body assembly as follows:


    1. Install the throttle body and connect the 2 water bypass hoses to the throttle body. Connect the water bypass hose with its discrimination mark downward.
    2.  
    3. Install the throttle body bracket and the 4 nuts. Tighten the nuts to 15 ft. lbs. (21 Nm).
    4.  
    5. Install the 2 bolts and nut holding the throttle body to the intake air connector and tighten them to 15 ft. lbs. (21 Nm).
    6.  
    7. Connect the engine wire clamp from the clamp bracket of throttle body.
    8.  
    9. Connect the accelerator pedal position sensor connector.
    10.  
    11. Connect the throttle control motor connector.
    12.  
    13. Connect the throttle position sensor connector.
    14.  
    15. Connect the accelerator cable.
    16.  

  2.  
  3. Install the intake air resonator.
  4.  
  5. Install engine cover.
  6.  
  7. Refill the engine cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Check the cooling system for leaks.
  12.  

3mz-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components (part 1).-3.3L (3MZ-FE) engine



Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components (part 2).-3.3L (3MZ-FE) 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 radiator lower air deflector.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the 4 nuts, then remove the front suspension upper brace center and 4 spacers. Temporarily tighten the 4 nuts.
  10.  
  11. Using a socket hexagon wrench 5, remove the 3 nuts, unfasten the 2 retainers, then remove the V-bank cover.
  12.  
  13. Remove the air cleaner cap sub-assembly as follows:


    1. Disconnect the mass air flow meter connector.
    2.  
    3. Disconnect the 4 vacuum hoses.
    4.  
    5. Disconnect the ventilation hose No. 2.
    6.  
    7. Disconnect the fuel vapor feed hose from the 2 hose clamps.
    8.  
    9. Loosen the 2 air cleaner cap bolts.
    10.  
    11. Loosen the air cleaner hose clamp bolt, then remove the air cleaner cap.
    12.  
    13. Remove the air cleaner filter element.
    14.  

  14.  
  15. Remove the throttle body assembly as follows:


    1. Disconnect the throttle motor connector.
    2.  
    3. Disconnect the water by-pass hose No. 2.
    4.  
    5. Disconnect the water by-pass hose No. 3.
    6.  
    7. Remove the 4 bolts, then remove the throttle body.
    8.  
    9. Remove the gasket from the intake air connector.
    10.  

  16.  

To install:

  1. Install the throttle body assembly as follows:


    1. Install a new gasket to the intake air connector.
    2.  
    3. Install the throttle body with the 4 bolts and tighten to 8 ft. lbs. (11 Nm).
    4.  
    5. Connect the water by-pass hose No. 3.
    6.  
    7. Connect the water by-pass hose No. 2.
    8.  
    9. Connect the throttle motor connector.
    10.  

  2.  
  3. Install the air cleaner cap sub-assembly and tighten the bolts to 44 inch lbs. (5 Nm).
  4.  
  5. Check the vacuum hose connections.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Refill the engine cooling system.
  10.  
  11. Check the cooling system for leaks.
  12.  
  13. Fit the 2 retainers, then install the V-bank cover and using a socket hexagon wrench 5, tighten the 3 nuts to 70 inch lbs. (7.9 Nm).
  14.  
  15. Install the front suspension upper brace center (if equipped). Torque the nuts to 59 ft. lbs. (80 Nm).
  16.  
  17. Install radiator lower air deflector.
  18.  
  19. Perform the system initialization procedure.
  20.  

3uz-FE Engine


Click image to see an enlarged view

Fig. Exploded view of the throttle body assembly and related components.-4.3L (3UZ-FE) 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. Drain the engine coolant.
  6.  
  7. Remove the 2 nuts and V-bank cover.
  8.  
  9. Remove the air cleaner inlet No. 1.
  10.  
  11. Remove the intake air connector pipe as follows:


    1. Disconnect the air hose and ventilation hose.
    2.  
    3. Remove the bolt.
    4.  
    5. Loosen the 2 hose clamps and remove the intake air connector pipe.
    6.  

  12.  
  13. Remove the throttle body as follows:


    1. Disconnect the water by-pass hose and water by-pass hose No. 7.
    2.  
    3. Disconnect the connector.
    4.  
    5. Remove the 2 bolts, 2 nuts, throttle body and gasket.
    6.  

  14.  

To install:

  1. Install the throttle body as follows:


    1. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Tighten the nuts and bolts to 13 ft. lbs. (18 Nm).
    2.  
    3. Connect the water by-pass hose and water by-pass hose No. 7.
    4.  
    5. Connect the connector.
    6.  

  2.  
  3. Install intake air connector pipe as follows:


    1. Install the intake air connector pipe with the bolt and 2 hose clamps. Tighten the hose clamps to 35 inch lbs. (4 Nm), and the bolt to 44 inch lbs. (5 Nm).
    2.  
    3. Connect the air hose and ventilation hose.
    4.  

  4.  
  5. Install air cleaner inlet No. 1.
  6.  
  7. Install the V-bank cover and tighten the nuts to 44 inch lbs. (5 Nm).
  8.  
  9. Refill the engine cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Check the cooling system for leaks.
  14.  
  15. Inspect the throttle control motor for operating sound as follows:


    1. Turn the ignition switch ON.
    2.  
    3. When turning the accelerator pedal position sensor lever, check the running sound of the motor. The motor should be running smoothly without friction sounds. If operation is not as specified, check the throttle control motor, wiring and ECM.
    4.  

  16.  
  17. Inspect the throttle position sensor as follows:


    1. Inspect the throttle position sensor.
    2.  
    3. Connect the hand-held tester (with CAN VIM) to the DLC3.
    4.  
    5. Turn the ignition switch ON.
    6.  
    7. Check that the MIL does not light up.
    8.  
    9. Check that, under the CURRENT DATA, THROTTLE POS (throttle valve opening percentage)is within the standard value below.

      Standard throttle valve opening percentage: 60% or more
       

    10.  
    11. If operation is not as specified, check the throttle position sensor, wiring and ECM.
    12.  

  18.  

 
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