Lexus ES manuals

Lexus ES: Removal

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / A25a-fxs (fuel) / Fuel Injector (for Direct Injection) / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during direct fuel injector assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

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Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Control System (for HV Model)

Pre-collision System (for HV Model)

Parking Support Brake System (for HV Model)*

Lighting System (for HV Model)

Memorize steering angle neutral point

Parking Assist Monitor System (for HV Model)

Panoramic View Monitor System (for HV Model)

Initialize power trunk lid system

Power Trunk Lid System (for HV Model)

  • Replacement of direct fuel injector assembly
  • Replacement of fuel pump assembly
  • Replacement of fuel pressure sensor
  • Replacement of throttle body with motor assembly
  • Cleaning the deposits from the throttle body with motor assembly
  • Replacement of EGR valve assembly
  • Gas leak from exhaust system is repaired

Inspection after repair
  • Poor idle, etc.
  • Engine start function, etc.

CAUTION:

  • Never perform work on fuel system components near any possible ignition sources.
  • Vaporized fuel could ignite, resulting in a serious accident.
  • Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
  • To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.

NOTICE:

  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System)
  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Navigation System)
  • This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. PRECAUTION

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

2. DISCHARGE FUEL SYSTEM PRESSURE

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3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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4. REMOVE INTAKE MANIFOLD

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5. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp from the fuel tube connector.

(b) Disconnect the fuel tube sub-assembly from the fuel pump assembly and fuel delivery pipe sub-assembly.

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6. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

CAUTION:

To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.

(a) Disconnect the ignition coil connector.

(b) for EGR Valve Bracket Connection Type:

(1) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

(c) for Cylinder Head Cover Sub-assembly Connection Type:

(1) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

Union Nut

Bolt

(2) Using an 8 mm socket wrench, remove the bolt.

(d) Loosen the 2 bolts of the fuel pump assembly.

(e) Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe and fuel pump assembly.

7. REMOVE FUEL PUMP ASSEMBLY

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8. REMOVE FUEL DELIVERY PIPE

NOTICE:

When replacing the fuel delivery pipe, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

(a) Disconnect the fuel pressure sensor connector.

(b) Disengage the clamp to disconnect the sensor wire from the fuel delivery pipe.

(c) Disconnect the 4 direct fuel injector assembly connectors.

NOTICE:

Make sure to disconnect the connectors carefully.

(d) Remove the 4 bolts and fuel delivery pipe with the 4 direct fuel injector assemblies from the cylinder head sub-assembly.

NOTICE:

  • Make sure not to touch or strike the tips of the direct fuel injector assemblies.
  • Pull and remove the fuel delivery pipe in a straight line without tilting it.

9. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

(a) Secure the fuel delivery pipe in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

NOTICE:

  • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe O-ring.
  • After removing the direct fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the fuel delivery pipe side.
  • Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.
  • Cover the tip of each direct fuel injector assembly to prevent it from being damaged.

(b) Remove the nozzle holder clamp from each direct fuel injector assembly.

(c) Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.

NOTICE:

Do not damage the area that contacts the O-ring.

(d) Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.

(e) Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.

10. REMOVE FUEL INJECTOR SEAL

(a) Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

NOTICE:

  • Excessively pinching the fuel injector seal may damage the groove of the direct fuel injector assembly.
  • If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.

(b) Remove the fuel injector seal from each direct fuel injector assembly.

READ NEXT:

 Inspection

INSPECTION PROCEDURE 1. INSPECT DIRECT FUEL INJECTOR ASSEMBLY NOTICE: This inspection is for checking the direct fuel injector assembly for an open or short. Because the direct fuel injector assembly

 Installation

INSTALLATION CAUTION / NOTICE / HINT NOTICE: This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts. Click here

 Fuel Injector (for Port Injection)

SEE MORE:

 Installation

INSTALLATION PROCEDURE 1. INSTALL ULTRASONIC SENSOR CUSHION SET HINT: Only perform this procedure when removing and installing the ultrasonic sensor cushion set. (a) Install the ultrasonic sensor cushion set as shown in the illustration. Install in this Direction - - 2. INSTALL REAR CO

 Installation

INSTALLATION PROCEDURE 1. INSTALL NO. 2 HV SUPPLY STACK SUB-ASSEMBLY CAUTION: Be sure to wear insulated gloves and protective goggles. (a) Install the No. 2 HV supply stack sub-assembly with the 4 nuts. Torque: 7.5 N·m {76 kgf·cm, 66 in·lbf} (b) Engage the claw. (c) Engage the clamp. (d) Install

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