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Fuel Delivery Pipe Replacement (L-CP-9LA)

Publication date: 2009-01-16
Reference number: L-CP-9LA

FUEL DELIVERY PIPE REPLACEMENT

FUEL DELIVERY PIPE REPLACEMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): L-CP-9LA, Date of Issue:  January 16, 2009
LEXUS: 2006 - 2007 GS 300/350; 2006 - 2008 IS 250/350; 2007 - 2008 LS 460/LS 460L
SERVICE CATEGORY: Special Service Campaign
SECTION: General
COPYRIGHT: © 2018 Lexus, a division of Toyota Motor Sales, USA License Agreement TMS1002

SERVICE INFORMATION

Model(s):

Section:

Bulletin No.:

Date: January 16, 2009

Subject: Special Service Campaign (Safety Recall) 9LA Certain 2006-2007 GS, 2006-2008 IS and 2007-2008 LS vehicles Fuel Delivery Pipe Replacement

Dear Dealer Principal:

Lexus will initiate a Special Service Campaign (SSC) on certain 2006 through 2007 GS 300/350, 2006 through 2008 model year IS 250/350, and 2007 through 2008 LS 460/LS 460L vehicles. The involved vehicles are equipped with aluminum fuel delivery pipes (fuel rails). Lexus has determined that ethanol fuels with low moisture content will corrode the internal surface of the fuel rails. As this condition progresses, the engine malfunction indicator light (MIL) may illuminate. Over time, the corrosion will create a pinhole resulting in fuel leakage.

The following information is provided to advise you and your staff of the owner notification phase of the campaign and your degree of involvement. Additional information may be found in the attached Lexus Q&A and customer notification letter.

OWNER NOTIFICATION DATE

Lexus will begin sending the Special Service Campaign notification in late January 2009 via first class mail.

IDENTIFICATION OF INVOLVED VEHICLES

VEHICLE VIN RANGE

MODEL VDS MY Serial Range
GS 300 BH96S 2006 5000028 - 5045859
GS 300 AWD CH96S 2006 0001017 - 0021080
GS 350 BE96S 2007 0007608 - 0028362
GS 350 AWD CE96S 2007 0001838 - 0012689
IS 250 BK262 2006 2000010 - 2021611
5000018 - 5025772
2007 2021159 - 2058542
5025773 - 5050845
2008 2057792 - 2061389
5050849 - 5053158
IS 250 AWD CK262 2006 2000003 - 2008675
5000013 - 5007908
2007 2008542 - 2019897
5007909 - 5015612
2008 2019898 - 2020648
5015613 - 5016546
IS 350 BE262 2006 2000000 - 2007084
5000018 - 5011869
2007 2006942 - 2013016
5011870 - 5017246
2008 2011547 - 2013594
5017247 - 5017817
LS 460 BL46F 2007 5000133 - 5051857
2008 5051858 - 5055333
LS 460L GL46F 2007 5000112 - 5020667
2008 5020680 - 5021639
NOTE: Dealers should always consult Dealer Daily or TIS to confirm VIN eligibility and to assure that the SSC is applicable. This will verify the vehicle is involved and has not already been completed by another dealer. TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected.

IMPLEMENTATION AT DEALERSHIPS

This SSC package contains the repair instructions, warranty claim procedures, and parts order information. Your dealership's affected VIN list will be sent to your service manager on January 21, 2009 via Next Day UPS delivery service. All associates who have a part in this campaign should be familiar with its contents.

PARTS AVAILABILITY AND ORDERING

The necessary parts can be ordered through your dealership's facing PDC. Lexus will monitor dealer orders for corrective action with any dealer who orders excessive quantities in relation to the affected vehicle population.

PARTS INFORMATION

Vehicle Part Description Part Number Quantity per Vehicle
GS 300 Pipe Kit, Fuel Delivery, No. 3 04008-18331 1
GS 350/IS 350 Pipe Kit, Fuel Delivery, No. 2 04008-18231 1
IS 250 Pipe Kit, Fuel Delivery, No. 4 04008-18431 1
LS 460/LS 460L Pipe Kit, Fuel Delivery, No. 1 04008-18138 1

In a small number of cases, based upon the inspection results you may need to replace the fuel injectors. Please keep all replaced fuel injectors for possible warranty parts recovery and inspections. If requested you will need a fuel injector shipping kit for dealers.

PARTS INFORMATION

Vehicle Part Description Part Number Insulator Color Quantity per Vehicle
GS 300/IS 250 Injector Assembly, Fuel 23209-39057-A0 Black 6 (as needed)
23209-39057-B0 Reddish Brown
GS 350/IS 350/LS 460/LS 460L Injector Assembly, Fuel 23209-39155-B0 Black 6 (GS/IS) or 8 (LS) (as needed)
23209-39155-C0 Reddish Brown
23209-39155-D0 Green

TOOLS AND EQUIPMENT

The following tools and equipment are required for this procedure.

WARRANTY CLAIM PROCESSING INSTRUCTIONS

Dealers are required to submit SSC claims using the information described below.

WARRANTY CLAIM INFORMATION

SSC Model Opcode Description Labor Hours(1)
9LA LS 460 /LS 460L 8506FA Replace the fuel delivery pipes 7.2
GS 300 8506FC Replace the fuel delivery pipes 3.2
GS 350 8506FG Replace the fuel delivery pipes 3.3
IS 250/IS 350 8506FJ Replace the fuel delivery pipes 3.3
(1) Above flat rate time(s) include 0.1 hour for campaign administrative cost per unit for the dealership. Lexus warranty will only accept one claim per vehicle under the terms of the SSC. Please ensure that your dealerships check Dealer Daily or TIS to see if the vehicle has been repaired under this SSC prior to servicing a vehicle.

In a small number of cases, based upon the inspection results you may need to replace the fuel injectors. Please utilize the following operation codes if fuel injector becomes necessary. 

WARRANTY CLAIM INFORMATION

SSC Model Opcode Description Labor Hours(1)
  LS 460/LS 460L 8506FB Replace the fuel delivery pipes and the injectors 6.8
GS 300 8506FD Replace the fuel delivery pipes and the injectors 2.9
GS 350 8506FH Replace the fuel delivery pipes and the injectors 3.0
IS 250/IS 350 8506FK Replace the fuel delivery pipes and the injectors 3.0
(1) Above flat rate time(s) include 0.1 hour for campaign administrative cost per unit for the dealership. Lexus warranty will only accept one claim per vehicle under the terms of the SSC. Please ensure that your dealerships check Dealer Daily or TIS to see if the vehicle has been repaired under this SSC prior  to servicing a vehicle.

The affected VIN information and operation codes will be downloaded and activated for dealerships to use on January 20, 2009.

IMPORTANT: Many vehicles subject to SSC 9LA are also a part of SSC 9LB (Rear Brake Caliper) and 9LC (Electric Power Steering). Lexus will only accept sublet charges for customer care amenities (car wash, fuel fill, rental, pick up and delivery) on the dealer claim for the SSC 9LA repair with the exception of GS 430/450h vehicles which should be claimed on the applicable SSC 9LB claim and RX 400h vehicles which should be claimed on the applicable SSC 9LC claim. It is important that your dealership perform all applicable SSC repairs in a single service visit and correctly submit the associated warranty claims.

CUSTOMER CARE

Lexus' usual customer care amenities (car wash, fuel fill-up and loaner vehicles) apply to this SSC. Specific details may be found in TIS in the General Procedures for Special and Limited Service Campaigns.

IMPORTANT: Many vehicles subject to SSC 9LA are also a part of SSC 9LB (Rear Brake Caliper) and 9LC (Electric Power Steering). Lexus will only accept sublet charges for customer care amenities (car wash, fuel fill, rental, pick up and delivery) on the dealer claim for the SSC 9LA repair with the exception of GS 430/450h vehicles which should be claimed on the applicable SSC 9LB claim and RX 400h vehicles which should be claimed on the applicable SSC 9LC claim.. It is important that your dealership perform all applicable SSC repairs in a single service visit and correctly submit the associated warranty claims.

Please review this entire package with your Service and Parts staff to familiarize them with its contents so they may properly implement this campaign as well as address any owner concerns that may arise regarding this Special Service Campaign  .

Thank you for your understanding. Your on-going care for these Lexus owners during this campaign protects our customers and their image of Lexus.

Sincerely,

Jerry Marcotti

Service and Parts Field Operations Manager

Attachments

CC: Customer Satisfaction Manager

General Manager

Parts Manager

Sales Manager

Service Manager

SPECIAL SERVICE CAMPAIGN (SAFETY RECALL) 9LA - Q&A

Certain 2006 - 2007 GS, 2006 - 2008 IS and 2007 - 2008 LS vehicles

Fuel Delivery Pipe Replacement

Q1: What is the condition? 

A1: The involved vehicles are equipped with aluminum Fuel Delivery Pipes (Fuel Rails). Lexus has determined that ethanol fuels with a low moisture content will corrode the internal surface of the fuel rails. As this condition progresses, the engine Malfunction Indicator Light (MIL) may illuminate. Over time, the corrosion will create a pinhole resulting in fuel leakage.

Q2: Are there any warnings that this condition exists? 

A2: Yes, the Malfunction Indicator Lamp (MIL) in the combination meter may illuminate.

Q3: Which and how many vehicles are involved? 

A3: There are approximately 214,500 vehicles involved.

VEHICLE MODEL INFORMATION

Model Year Model Approx UIO
2006 GS 300 43,700 (24,500 2WD, 19,200 AWD)
2007 GS 350 23,700 (14,000 2WD, 9,700 AWD)
2006 - IS 250 85,800 (54,000 2WD, 31,800 AWD)
2006 - IS 350 24,900
2007 - LS460/LS460L 36,400 (25,500 LS460, 10,900

Q4: Are there any other Toyota or Lexus vehicles involved? 

A4: No, this specific condition only affects certain 2006 through 2007 GS 300/350, 2006 through 2008 IS 250/350, and 2007 through 2008 model year LS460/LS460L vehicles.

Q5: What is the production period of the affected vehicles? 

A5: The affected vehicles were produced:

VEHICLE MODEL PRODUCTION RANGE

Model Year Model Production Range
2006 GS 300 Early January 2005 - Late July 2006
2007 GS 350 Mid-June 2006 - Late September 2007
2006 - 2008 IS 250 Late August 2005 - Mid-September 2007
2006 - 2008 IS 350 Late August 2005 - Late September 2007
2007 - 2008 LS460/LS460L Early May 2006 - Early September 2007

Q6: How many incidents of this condition have been reported? 

A6: There have been no reported cases of fire. However, 46 cases of Malfunction Indicator Lamp (MIL) illumination, the corrosion condition and/or fuel leakage were reported in the affected vehicles in the United States.

Q7: Have there been any accidents reported? 

A7: No. There have been no accidents reported which relate to this condition.

Q8: What is Lexus going to do? 

A8: Owners of the involved vehicles will receive a Safety Recall Notification by first class mail in late January 2009. Any Lexus dealer will replace the fuel delivery pipes with a newly designed one at NO CHARGE to the vehicle owner.

Q9: How long will the repair take? 

A9: The repair will take approximately three hours for GS and IS vehicles or approximately seven hours for LS vehicles. However, depending upon the dealer's work schedule, it may be necessary to make the vehicle available for a longer period of time.

Q10: What should an owner do if they experience the condition, or have immediate concerns about their vehicle? 

A10: If an owner has any immediate concerns they are requested to contact their local Lexus dealer for diagnosis, and if applicable, repair.

OWNER NOTIFICATION LETTER SPECIAL SERVICE CAMPAIGN 9LA

Special Service Campaign 9LA

Certain 2006 - 2007 GS, 2006 - 2008 IS and 2007 - 2008 LS vehicles

Fuel Delivery Pipe Replacement (Safety Recall)

Dear Lexus Customer:

This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Lexus has decided that a defect, which relates to motor vehicle safety, exists in certain 2006 through 2007 GS 300/350, 2006 through 2008 model year IS 250/350, and 2007 through 2008 LS 460/LS 460L vehicles.

What is the condition? 

Your vehicle is equipped with aluminum Fuel Delivery Pipes (Fuel Rails). Lexus has determined that ethanol fuels with a low moisture content will corrode the internal surface of the fuel rails. As this condition progresses, the engine Malfunction Indicator Light may illuminate. Over time, the corrosion will create a pinhole resulting in fuel leakage. In the worst case, fuel leakage in the presence of an ignition source could result in a fire.

What will Lexus do? 

Your Lexus dealer will replace the involved Fuel Delivery Pipes with newly designed ones at NO CHARGE  .

What should you do? 

This is an important Safety Recall 

Please make an appointment with your authorized Lexus dealer to replace the involved Fuel Delivery Pipes as soon as possible. The repair will take approximately three hours for GS and IS vehicles. LS vehicles will require approximately seven hours for the repair. However, depending upon the dealer's work schedule, it may be necessary to make your vehicle available for a longer period of time.

We request that you present this notice to the dealer at the time of your service appointment. 

If you would like to update your vehicle ownership or contact information, you may do so by registering at www.lexus.com/owners  . You will need your full 17-digit Vehicle Identification Number (VIN) to input the new information.

What if you have other questions? 

Your local Lexus dealer will be more than happy to answer any of your questions and set up an appointment to perform the repair  . If you require further assistance, you may contact the Lexus Customer Assistance Center at 1-800-255-3987 Monday through Friday, 5:00 am to 6:00 pm, Saturday 7:00 am through 4:00 pm Pacific Standard Time.

If you believe that the dealer or Lexus has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153), or go to http://www.safercar.gov.

If you are a vehicle lessor, Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

We have sent this notice in the interest of your continued satisfaction with our products, and we sincerely regret any inconvenience this condition may have caused you.

Thank you for driving a Lexus.

Sincerely,

Lexus Division

TOYOTA MOTOR SALES, U.S.A., INC.

TECHNICAL INSTRUCTIONS FOR SPECIAL SERVICE CAMPAIGN 9LA FUEL DELIVERY PIPE REPLACEMENT 2006-2008 IS250/350

G07671373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Revised January 26, 2011 

TECHNICAL INSTRUCTION REVISION NOTICE: 

OPERATION FLOW CHART

G07671374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

I. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE
AFFECTED VIN RANGE

Vehicle Model Year WMI VIN Range
VDS Range
IS250 2006 JTH BK262 2000010 - 2021611
5000018 - 5025772
2007 2021159 - 2058542
5025773 - 5050845
2008 2057792 - 2061389
5050849 - 5053158
IS250 AWD 2006 CK262 2000003 - 2008675
5000013 - 5007908
2007 2008542 - 2019897
5007909 - 5015612
2008 2019898 - 2020648
5015613 - 5016546
IS350 2006 BE262 2000000 - 2007084
5000018 - 5011869
2007 2006942 - 2013016
5011870 - 5017246
2008 2011547 - 2013594
5017247 - 5017817

II. PREPARATION

A. Tools
  • Standard hand tools
  • Torque wrench
  • 22 mm union nut wrench
  • SST: (non-essential) 09612-24014 (09617-24011)
  • SST: Stud Bolt - 04007-32331 (2 stud bolts have been included in each Service Manager's Package.)
  • SST: 09260-39015 Injector seal tool set. (02968-03020, 09268-03010) Lexus drawer 1
B. Equipment
  • Techstream
C. Material
  • Protective Tape
  • Wooden boards (for clamping purposes)
D. IS 250 Parts
IS 250 PARTS INFORMATION

Model Part Number Part Description Qty
IS 250 04008-18431 Pipe Kit, Fuel Delivery, No. 4 1

The kit listed above includes the following parts: 

An illustration of the parts replaced and their installation location(s) have been provided. Please reference the tables below and on the next page.

KIT PARTS INFORMATION

Part Number Part Description Qty Illustration Installation Location(s)
17176-31050 Gasket (Air Surge Tank to Intake Manifold) 3
G07671375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
17177-31020 Gasket (No. 1 Intake Manifold to Head) 2
G07671376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
22271-31030 Gasket (Throttle Body) 1
G07671377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
23807-31020 Fuel Delivery Pipe 1
G07671378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23808-31010 No 2 Fuel Delivery Pipe 1
G07671379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
The parts listed below are packages together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23915-46011 Fuel Pump Insulator 1
G07671380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90301-06016 O-Ring 3
G07671381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90301-06018 O-Ring 6
G07671382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
90523-05007 E-Ring 9
G07671383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
The parts listed below are packages together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23255-31010 Fuel Injector Seal 12
G07671384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
23256-74010 No.1 Fuel Injector Backup Ring 9
G07671385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23257-74010 No.2 Fuel Injector Backup Ring 9
G07671386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23258-28011 No.3 Fuel Injector Backup Ring (Flat) 9
G07671387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23279-74010 Gasket (Fuel Pressure Pulsation Damper) 2
G07671388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
23291-31011 Injector Vibration Insulator 6
G07671389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
90430-08014 Gasket (Cold Start Injector) 2
G07671390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
90430-12026 Gasket 2
G07671391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11

Based upon the inspection results you may need to replace the fuel injectors. Please keep all fuel injectors for possible parts recovery and inspections. If requested you will need a fuel injector shipping kit for dealers. 

KIT PARTS INFORMATION

Model Part No. Insulator Color Part Name Qty/Unit
IS 250 23209-39057-A0(1) or Black Injector Assy, Fuel 6 (if needed)
23209-39057-B0(1) Reddish Brown
(1) Either injector listed for the vehicle type may be installed; however, make sure that all  injectors installed on the vehicle are the same type. The injector may be identified by the injector insulator color. Please see page 30 for addition information.
E. IS 350 Parts
IS 350 PARTS INFORMATION

Model Part Number Part Description Qty
IS 350 04008-18231 Pipe Kit, Fuel Delivery, No. 2 1

The kit listed above includes the following parts: 

An illustration of the parts replaced and their installation location(s) have been provided. Please reference the tables below and on the next page.

KIT PARTS INFORMATION

Part Number Part Description Qty Illustration Installation Location(s)
17176-31060 Gasket (Air Surge Tank to Intake Manifold) 1
G07671392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
17177-31060 Gasket (No. 1 Intake Manifold to Head) 2
G07671393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
22271-31020 Gasket (Throttle Body) 1
G07671394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
23807-31070 Fuel Delivery Pipe 1
G07671395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23808-31020 No 2 Fuel Delivery Pipe 1
G07671396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
The parts listed below are packages together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23915-46011 Fuel Pump Insulator 1
G07671397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90301-06016 O-Ring 3
G07671398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90301-06018 O-Ring 6
G07671399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
23291-31011 Injector Vibration Insulator 6
G07671400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
The parts listed below are packages together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23255-31010 Fuel Injector Seal 12
G07671401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
23256-74010 No.1 Fuel Injector Backup Ring 9
G07671402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23257-74010 No.2 Fuel Injector Backup Ring 9
G07671403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23258-28011 No.3 Fuel Injector Backup Ring (Flat) 9
G07671404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 10 & 11
23279-74010 Gasket (Fuel Pressure Pulsation Damper) 2
G07671405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90430-12026 Gasket 2
G07671406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11
90523-05007 E-Ring 9
G07671407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 11

Based upon the inspection results you may need to replace the fuel injectors. Please keep all fuel injectors for possible parts recovery and inspections. If requested you will need a fuel injector shipping kit for dealers. 

KIT PARTS INFORMATION

Model Part No. Insulator Color Part Name Qty/Unit
IS350 23209-39155-B0(1) or Black Injector Assy, Fuel 6 (if needed)
23209-39155-C0(1) or Reddish Brown
23209-39155-D0(1) Green
(1) Either injector listed for the vehicle type may be installed; however, make sure that all injectors installed on the vehicle are the same type. The injector may be identified by the injector insulator color. Please see page 30 for addition information.
F. PARTS INSTALLATION LOCATION(S)
G07671408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

III. WORK PROCEDURE TABLE OF CONTENTS

IMPORTANT: Only partial reinstallation steps are included in these Technical Instructions; please reference TIS for additional assistance if needed.

IV. BACKGROUND

The involved vehicles are equipped with aluminum Fuel Delivery Pipes (Fuel Rails). Lexus has determined that ethanol fuels with a low moisture content will corrode the internal surface of the fuel rails. As this condition progresses, the engine Malfunction Indicator Light (MIL) may illuminate. Over time, the corrosion will create a pinhole resulting in fuel leakage.

G07671412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WORK PROCEDURE

V. SAFETY PRECAUTIONS

A. PRECAUTIONS WHEN WORKING ON THE FUEL SYSTEM
IMPORTANT:
  • ALWAYS REMEMBER "SAFETY FIRST". 
  • IMMEDIATELY WIPE UP ANY SPILLED FUEL. 
  • BE EXTREMELY CAREFUL WHEN HANDLING FUEL TO PREVENT FIRES FROM OCCURRING. 
  • BEFORE REMOVING ANY FUEL SYSTEM PART, DRAIN ALL FUEL TO PREVENT SPILLING. 
  • BEFORE WORKING ON THE FUEL SYSTEM, PERFORM THE FOLLOWING SAFETY CHECK LIST. 
B. SAFETY CHECKLIST
  1. AIR VENTILATION 
    • Perform work in a well ventilated area.
    • DO NOT  work underground or in an area where fuel vapors may fill the room due to poor ventilation.
    • Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
    • Dry all cloths that have come in contact with fuel in a well ventilated area and dispose of them properly (according to applicable local regulations).
      G07671413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED 
    • Fires and ignition sources are prohibited while working on the fuel system.
    • Clearly display the sign found on the next page stating "WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES". 
    • Smoking is prohibited near the work area.
    • DO NOT  work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
    • DO NOT  use work lamps or any other electrical appliance due to the risk of sparks flying from the power switch or a rise in temperature.
    • DO NOT  use metal hammers while working, due to the risk of flying sparks.
    • DO NOT  start any engine or perform any of the above in neighboring work bays.
      G07671414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. FIRE EXTINGUISHER 
    • Have a fire extinguisher ready and available before beginning work.
  4. PREVENT STATIC ELECTRICITY 
    • To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition.
    • Place appropriate warning cones or stand signs around the area as a caution.
      G07671415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. PRECAUTIONS WHEN USING A LIFT 
    • For bays equipped with auto lifts, cover all access cover joints with duct tape.
    • In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. Dissipate fuel vapors until the smell is gone.
      G07671416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. PREVENT THE FUEL FROM SPRAYING 
    • When disconnecting any fuel pipes or connectors there may still be some pressure remaining, even after discharging the system. To prevent the fuel from spraying, cover the pipe with a shop rag before disconnecting.
    • Remember to always wear protective goggles especially when disconnecting fuel pipes.
      G07671417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS 
    • Do not allow the fuel to come in contact with any parts made of rubber or leather.
      G07671418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. ASSIGN A SAFETY SUPERVISOR 
    • Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area.
  9. WORK SCHEDULING 
    • Work must be completed the same day.
    • As a general rule, do not stop work midway. If work must stop midway, inform your safety supervisor.
      G07671419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. WHEN CONNECTING THE FUEL PIPE 
    • Any amount of damage or small foreign object (dust, a piece of thread, rust, etc.) may cause a fuel leak. Be thorough when inspecting and cleaning the fuel pipes and seal surface areas.
      G07671420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

VI. FUEL DELIVERY PIPE REPLACEMENT

A. REMOVE THE ENGINE COVERS AND DISCHARGE THE FUEL SYSTEM
G07671421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. CHECK FOR DTCs 
    1. If DTC(s) are present, verify them, view and record the freeze frame data, and perform the necessary repairs.
  2. REMOVE THE ENGINE ROOM COVER & V-BANK COVER SUB-ASSEMBLY 
    • DO NOT DISCONNECT ANY PART OF THE FUEL SYSTEM UNTIL YOU HAVE DISCHARGED THE FUEL SYSTEM PRESSURE. 
    • EVEN AFTER DISCHARGING THE FUEL SYSTEM PRESSURE, PLACE A PIECE OF CLOTH AROUND THE FITTINGS AS YOU SEPARATE THEM TO REDUCE THE RISK OF FUEL SPRAYING ON YOURSELF, IN THE ENGINE COMPARTMENT, AND ONTO OTHER PARTS. 
  3. DISCHARGE THE FUEL SYSTEM PRESSURE 
    1. Remove the relay block upper cover No. 2.
    2. Remove the fuel pump (F/PMP) 25 amp fuse.
    3. Start the engine.
    4. After the engine has stopped, turn the ignition switch OFF.
    5. Crank the engine again to relieve any existing fuel pressure.
      NOTE: DTC P0171/25 and/or P0191/49 may be set.
    6. Remove the fuel cap to discharge the fuel tank pressure.
    7. Record the radio station presets.
      NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed after turning the ignition OFF.
    8. Disconnect the negative (-) battery cable.
    9. Reinstall the fuel pump (F/PMP) 25 amp fuse.
    10. Reinstall the relay block upper cover No. 2.
    11. Reinstall the fuel cap.
      G07671422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
B. REMOVE THE INTAKE MANIFOLD

IS250 (4GR-FSE) - INTAKE MANIFOLD REMOVAL 

IS350 (2GR-FSE) - INTAKE MANIFOLD REMOVAL 

  1. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
      NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
      G07671423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt, clip and inlet air cleaner.
      G07671424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 
    1. Disconnect the MAF connector and remove the wiring from the clamp.
    2. Disconnect the NO.2 ventilation hose.
      G07671425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the vacuum hose clamp.
      G07671426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Loosen the hose clamp bolt.
    5. Remove the 4 clips and air cleaner cap with air cleaner hose.
      G07671427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE THROTTLE BODY ASSEMBLY 
    1. Disconnect the throttle body connector.
    2. Remove the 4 bolts and throttle body assembly and gasket.
      G07671428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place protective tape over the surge tank opening to prevent foreign objects from entering from the old gasket above.
      G07671429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the purge VSV connector.
    2. Disconnect the vacuum hose from the purge VSV.
      G07671430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the ventilation hose from the intake manifold.
    4. Disconnect the union to check valve hose from the intake air surge tank.
    5. Disconnect the wire harness clamp from the intake air surge tank.
      G07671431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the 4 injector connectors.
    7. Disconnect the 3 wire harness clamps from the intake air surge tank.
    8. Disconnect the water by-pass hose from the intake air surge tank.
      G07671432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 bolts from the intake air surge tank, see illustration below.
      G07671433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a long hexagon 5 mm, remove the 6 bolts and using a 10mm socket remove the 2 nuts.
    11. Remove the intake surge tank and gasket.
      G07671434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Place protective tape over the intake manifold openings to prevent foreign objects from entering.
      G07671435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE INTAKE MANIFOLD 
    1. Pinch and pull the fuel tube connector to disconnect the connector from the delivery pipe.
      NOTE:
      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O- rings or cause leaks in the seal between the pipe and connector.
      • Do not use any tools to separate the pipe and connector.
      • Do not forcefully bend or twist the nylon tube.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
        G07671436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place a plastic bag over the fuel tube, seal bag to prevent damage or foreign objects from entering.
    3. Place protective tape around the sides of the pipe to prevent damage.
      G07671437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
      G07671438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place protective tape on the old gasket and place it over the cylinder head opening to prevent foreign objects from entering.
  7. C. REMOVE FUEL DELIVERY PIPE 
    G07671439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
IS250 (4GR-FSE) - INTAKE MANIFOLD REMOVAL
  1. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
      NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
      G07671440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt, clip and air cleaner inlet.
      G07671441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 
    1. Disconnect the MAF connector and remove the wiring from the clamp.
    2. Disconnect the No. 2 Ventilation hose.
      G07671442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the vacuum hose clamps.
      G07671443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Loosen the hose clamp bolt.
    5. Remove the 4 clips and air cleaner cap with air cleaner hose.
      G07671444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE THROTTLE BODY ASSEMBLY 
    1. Disconnect the throttle body connector.
    2. Remove the 4 bolts and throttle body assembly and gasket.
      G07671445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place protective tape over the surge tank opening to prevent foreign objects from entering from the old gasket above.
      G07671446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the purge VSV connector.
    2. Disconnect the vacuum hose from the purge VSV.
      G07671447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Disconnect the wire harness clamp.
    5. Disconnect the union to check valve hose from the intake air surge tank.
      G07671448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the cold start injector connector.
    7. Remove the bolt and 2 gaskets, and disconnect the fuel tube from the cold start injector.
      NOTE: Do not fold or bend the hose.
      G07671449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the ventilation hose from the intake manifold.
      G07671450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disconnect the 2 wire harness clamps from the intake air surge tank.
    10. Disconnect the water by-pass hose from the intake air surge tank.
      G07671451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the 3 bolts from the intake air surge tank, see illustration below.
      G07671452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Using a hexagon 5 mm, remove the 6 bolts, then using a 10mm socket remove the 2 nuts.
      G07671453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Disconnect the connector clamp from the intake air surge tank.
    14. Remove the intake air surge tank and gasket.
      G07671454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Place protective tape over the intake manifold openings to prevent foreign objects from entering.
      G07671455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE INTAKE MANIFOLD 
    1. Disconnect the connector for the SCV.
    2. Disconnect the SCV position sensor connector.
    3. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
    4. Place protective tape on the old gasket and place it over the cylinder head opening to prevent foreign objects from entering.
      G07671456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
C. REMOVE FUEL DELIVERY PIPE
  1. REMOVE NO. 1 FUEL PIPE 
    1. Disconnect the ignition coil connector illustrated.
    2. Disconnect the 3 fuel hoses.
    3. Remove the 2 bolts and No. 1 fuel pipe.
      NOTE:
      • Insert a hose plug into the hose.
      • Wipe away any spilt fuel with a shop rag.
        G07671457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FUEL PRESSURE PULSATION DAMPER 
    1. Disconnect the pulsation damper connector.
      NOTE: When the fuel pressure pulsation damper is removed, be certain to disconnect the connector to prevent it from being damaged by tools.
      G07671458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST or a 22 mm wrench, remove the fuel pressure pulsation damper and 2 gaskets from the fuel pump.

      SST 09617-24011 

      NOTE:
      • Do not blow pressurized air into the pulsation damper. The air pressure may damage the internal diaphragm.
        G07671459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place protective tape over the fuel pump and fuel tube to prevent damage.
      G07671460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE WATER HOSE JOINT (for IS350 2GR-FSE only) 
    1. Remove the 2 bolts and disconnect the water hose joint.
      G07671461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FUEL PUMP ASSEMBLY AND NO. 2 FUEL PIPE 
    IMPORTANT:

    WHEN REPLACING FUEL PIPE NO. 2, THE FUEL PUMP MUST BE REMOVED. THIS MUST BE DONE TO PREVENT SEAL DAMAGE AND THE TWISTING OF THE FUEL PIPE, FAILURE TO DO SO MAY RESULT IN A FUEL LEAK! 

    1. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union.
      NOTE:
      • Must be absolutely no free play in the union on the fuel pump side.
      • If the union on the fuel pump side has free play, replace the fuel pump  .
        G07671462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts on the delivery pipe side.
      G07671463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts from the fuel pump.
      G07671464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel pump and fuel pump insulator.
      NOTE:
      • Wipe away any spilt fuel with a shop rag.
      • Do not apply excessive force to the heater hose and coolant pipe.
        G07671465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place protective tape on the old insulator and place it over the head cover opening to prevent foreign objects from entering.
      G07671466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 2 FUEL PIPE 
    1. Hand tighten the 2 SST stud bolts in the delivery pipe's bolt attachment holes. (torx® side up)

      SST 04007-32331 

      G07671467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel pipe from the fuel delivery pipe.
    3. Remove the 2 stud bolts.
      NOTE:
      • Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      • Fuel Pipes may be extremely tight, use caution while removing as to not cause damage.
        G07671468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 3 FUEL PIPE 
    1. Remove the 4 bolts.
      G07671469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hand tighten the 2 stud bolts to the delivery pipe. (torx® side up)
      NOTE: Attach the stud bolts diagonal from each as shown in the illustration.
      G07671470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel pipe from the fuel delivery pipe.
    4. Remove the 2 stud bolts.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 2 FUEL DELIVERY PIPE 

    To prevent possible injector damage, please proceed with the following steps in the order indicated.

    1. Disconnect the 3 wire harness clamps and remove the 2 bolts and 2 nuts.
    2. Remove the fuel delivery pipe.
    3. Disconnect the 3 electrical connectors by hand  .
      NOTE:
      • Do not exert extreme force while removing the fuel pipe, this may lead to injector damage.
      • Carefully move the fuel pipe back and forth from end to end while firmly pulling up will assist with removal.
      • Injectors may remain in the cylinder head during fuel pipe removal; if this occurs, carefully disconnect the electrical connector to prevent injector damage.
      • Be extremely careful not to touch or strike the tips of the injectors.
        G07671472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 injector vibration insulators from the cylinder head.
      G07671473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 FUEL DELIVERY PIPE 

    To prevent possible injector damage, please proceed with the following steps in the order indicated.

    1. Disconnect the fuel pressure sensor connector, wire harness clamps and remove the 2 bolts and 2 nuts.
    2. Lift the fuel delivery pipe up until it is horizontally level with the stud bolts.
    3. Carefully pull up on the front side of the fuel delivery pipe.
    4. Carefully pull the fuel delivery pipe up so that the fuel pressure sensor and the heater hose do not touch.
    5. Disconnect the 3 electrical connectors by hand  .
      NOTE:
      • Do not exert extreme force while removing the fuel pipe, this may lead to injector damage.
      • Carefully move the fuel pipe back and forth from end to end while firmly pulling up will assist with removal.
      • Injectors may remain in the cylinder head during fuel pipe removal; if this occurs, carefully disconnect the electrical connector to prevent injector damage.
      • Be extremely careful not to touch or strike the tips of the injectors.
      • To avoid damage to both components, do not allow the fuel pressure sensor to come in contact with the heater hose.
        G07671474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 injector vibration insulators from the cylinder head.
      G07671475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
D. REMOVE AND INSPECT FUEL INJECTORS
  1. REMOVE FUEL INJECTORS 
    1. Clamp the fuel injector assembly in a vise with wooden boards placed in between the vise and assembly.
      NOTE:
      • Be extremely careful not to touch or strike the tips of the injectors.
      • Use both hands when clamping the fuel injector assembly to the vise.
        G07671476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. With the fuel injector assembly clamped in the vise, remove the fuel delivery pipe by pulling straight back from the assembly as shown in the illustration.
      NOTE:
      • Clamp the vise to the areas illustrated on the fuel injector assembly. Do not clamp areas which are not indicated in the left illustration.
      • Do not over tighten. Also, do not allow the connector to come in contact with the vise.
        G07671477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nozzle holder clamp from the injectors.
      G07671478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: For reinstallation, attach a tag or label to the injector shaft.
      G07671479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Repeat steps a) ~ c) for the remaining injectors.
  2. FUEL INJECTOR INSPECTION 
    1. Inspect the condition of the fuel injector assembly as illustrated, and assess with the chart below.
      G07671480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CONDITION OF FUEL INJECTOR ASSEMBLY

      Condition of fuel injector assembly Results
      No white adhesion at entrance Reuse the fuel injector.
      White adhesion at entrance Replace ALL  fuel injectors with new ones. Keep used injectors for possible parts recovery and inspection.
      NOTE:
      • Either injector listed in the parts table for a particular vehicle type may be installed; however, make sure that all  injectors installed on the vehicle are the same color.
      • IS250 23209-39057-A0 = Black
      • IS250 23209-39057-B0 = Reddish Brown
      • IS350 23209-39155-B0 = Black
      • IS350 23209-39155-C0 = Reddish Brown
      • IS350 23209-39155-D0 = Green
        G07671481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FUEL PRESSURE SENSOR 
    1. Clamp the No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Using a 24 mm wrench, remove the fuel pressure sensor and gasket.
      G07671482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL PRESSURE SENSOR 
    1. Clamp a NEW  No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Install a NEW  gasket to the fuel pressure sensor.
    3. Using SST, install the fuel pressure sensor to the No. 1 delivery pipe.
      G07671483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CALCULATE THE FUEL PRESSURE SENSOR TORQUE VALUE 
    IMPORTANT:
    • The calculated torque (C) is the value at which the torque wrench MUST be set. 
    • To determine the calculated torque, READ  , and CLOSELY follow the steps below. 
    • If using the formula L1 and L2 MUST be measured in feet. 
    1. Measure the length of the torque wrench from the center of the drive to the middle of the handle as shown in the illustration (L2)
    2. Determine the calculated torque (C) value to set the wrench to by referencing the table below.
      FUEL PRESSURE SENSOR TORQUE SPECIFICATIONS

      Torque Wrench Length - L2 (inches) Calculated Torque (ft lbs)
      10" 27.6
      12" 28.1
      14" 28.5
      16" 28.8
      18" 29
      20" 29.2
      NOTE: The torque wrench union nut MUST  be used when using the values in this table.

      Calculated Torque Formula: C= (T) x L2 / (L1 + L2) 

      G07671484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      LEGENDS REFERENCE CHART

      C Calculated Torque (ft.lbf)
      T Specified torque (ft.lbf) (31 ft.lbf)
      L1 Torque wrench adapter length or length of tool (ft.)
      L2 Length of torque wrench (ft.)
  6. REMOVE FUEL RELIEF VALVE ASSY 
    1. Clamp the No. 2 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Using a 17 mm union nut wrench, remove the fuel relief valve and gasket.
      G07671485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL RELIEF VALVE ASSY 
    1. Clamp a NEW  No. 2 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Install a NEW  gasket to the fuel relief valve.
    3. Using union nut wrench 17 mm, install the fuel relief valve to the No. 2 delivery pipe.

      Torque Specification: 36 N.m (367 kgf.cm, 27 ft.lbf) 

      G07671486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL INJECTOR SEAL 
    1. Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.
    2. Repeat step a for the remaining injectors.
      NOTE: If an injector is dropped or the tips of the injectors are struck, replace it with a NEW  one.
      G07671487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the injector area shown in the illustration. Using a piece of cloth, clean carbon deposits from the injector and its grooves.
      NOTE:
      • Do not clean the tip of the injector.
      • Do not use a wire brush to clean the injector.
      • If an injector is dropped or the tips of the injectors are struck, replace it.
        G07671488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply engine oil to the injector contact surface of SST (guide). Then attach SST (guide) to the injector with the tapered inner portion facing the tip of the injector, as shown in the illustration.

      SST 09260-39015 (09268-03020) 

      NOTE: Due to the specific tolerances needed to seat the seals it will be difficult to slide the SST. Slowly wiggle it from side to side while sliding it up the injector little by little.
      G07671489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a NEW  injector seal to SST (holder).

      SST 09260-39015 (09268-03010) 

      NOTE: Be careful not to install the injector seal to the SST (holder) at an angle. Doing so will stretch the seal.
      G07671490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install SST (holder with injector seal) to the tip of the injector. Slide the seal downward into the injector groove (injector connector side) with your fingers, as shown in the illustration.

      SST 09260-39015 (09268-03010, 09268-03020) 

      G07671491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST (holder), gently press downward on the injector seal (injector connector side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.

      SST 09260-39015 (09268-03010, 09268-03020) 

      NOTE:
      • Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.
      • When using SST (guide) to settle the seal into the groove, SST (guide) only needs to be slid upward to the position labeled A in the illustration.
      • After using SST (guide) to settle the seal into the groove, return SST (guide) to its position labeled B in the illustration.
        G07671492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install a NEW  injector seal to SST (holder).
      G07671493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install a NEW  injector seal to the injector groove (injector tip side) as shown in the illustration.
    8. Check that the seal covers the circumference of the injector groove as shown in the illustration.
      NOTE: Make sure that the seal does not slip into the welded groove of the injector shown in the illustration. If it does, replace it with a NEW  one.
      G07671494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.
      G07671495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using SST (holder), gently press downward on the injector seal (injector tip side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.
      NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.
      G07671496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.
      G07671497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. After installing the seals, check that the seal is not scratched, deformed or protruding from the injector groove.
      NOTE:
      • If the seal is scratched, deformed or protruding from the groove, replace it with a NEW  one.
      • The 2nd seal from the injector tip is partially on a tapered surface so after installation it may slide up to 0.5 mm.
    13. Repeat steps  a) ~  k), for the remaining injectors.
      G07671498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REPLACE FUEL INJECTOR O-RING, BACKUP RINGS AND E-RING 
    1. Remove the O-ring, backup rings and E-ring from the fuel injector.
    2. Install a NEW  O-ring, NEW  backup rings (No. 1, No. 2, No. 3) and NEW  E-ring to the fuel injector as shown in the illustration.
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
        G07671499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align and install the No.1 and No.2 back up rings to the fuel injector's tapered surface.
    3. Repeat steps a) ~ b), and install the 6 O-ring, NEW  backup rings (No. 1 No. 2, and No. 3) and NEW  E-ring.
      G07671500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FUEL INJECTOR ASSEMBLY 
    1. Install the injector nozzle holder clamp.
    2. Apply gasoline to the fuel injector's O-ring and into the attachment hole of the fuel delivery pipe.
      NOTE: Apply gasoline on both the O-ring and into the attachment hole. Lubricant will run out immediately after insertion if only applied to the O-ring side.
      G07671501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.
    4. Repeat steps a) ~ c) for the remaining injectors.
      NOTE:
      • Make sure that there is no gap between the delivery pipe and clamp.
        G07671502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
E. FUEL PIPE INSTALLATION
  1. INSTALL NO. 1 FUEL DELIVERY PIPE 
    1. Install 3 NEW  injector vibration insulators to the cylinder head.
    2. Apply lubricant to the installation hole of the injector.
      G07671503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While gently raising the front of the delivery pipe, carefully insert the fuel delivery pipe on to the cylinder head's stud bolts. Do not allow the fuel pressure sensor and heater hose come in contact.
      NOTE:
      • If an injector is dropped or the tips of the injectors are struck, replace it with a NEW  one.
      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        G07671504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the delivery pipe's attachment holes with the stud bolts and install the delivery pipe without letting the fuel pressure sensor and heater hose come in contact.
    5. Connect the 3 electrical fuel injector connectors.
      G07671505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.
      G07671506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

    8. Connect the fuel pressure sensor connector and wire harness clamps.
      G07671507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 2 FUEL DELIVERY PIPE 
    1. Install 3 NEW  injector vibration insulators to the cylinder head.
    2. Apply lubricant to the installation holes of the injectors.
    3. Connect the 3 electrical fuel injector connectors.
      G07671508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.
      NOTE:
      • If an injector is dropped or the tips of the injectors are struck, replace it with a NEW  one.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        G07671509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Reinstall the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

    6. Connect the 3 wire harness clamps to the fuel delivery pipe.
      G07671510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REINSTALL NO. 3 FUEL PIPE 
    1. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.
    2. Install a NEW  O-ring, NEW backup rings (No. 1 No. 2, and No. 3) and NEW  E-ring to the fuel injector as shown in the illustration.
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
        G07671511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align and install the No.1 and No.2 back up rings to the No. 3 fuel pipe's tapered surface.
      G07671512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Hand tighten the 2 stud bolts to the delivery pipe bolt attachment holes diagonally as illustrated. (torx® side up)
    4. Place protective tape over screw holes without stud bolts to prevent lubricant from entering.
    5. Apply gasoline to the No. 3 fuel pipe's O-ring and into the attachment hole of the delivery pipe's No. 3 fuel pipe.
      NOTE:
      • Failure to lubricate both o-ring and attachment hole, may damage the seal.
        G07671513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the protective tape and clean the delivery pipe attachment surface.
    7. Insert the 2 stud bolts through the No. 3 fuel pipe.
      G07671514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Press the fuel pipe and delivery pipe together by hand until there is no gap between them.
    9. Remove the 2 stud bolts once the pipes are together.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Clean the screw holes of dirt and gasoline, and then insert and tighten the 4 bolts in the order shown in the illustration.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 2 FUEL PIPE 
    IMPORTANT:

    WHEN REINSTALLING FUEL PIPE NO. 2 AND THE FUEL PUMP, FOLLOW THE TEMPORARY INSTALLATION, TIGHTENING AND OTHER PROCEDURES SHOWN TO PREVENT DAMAGE TO ALL SEALING SURFACES. 

    1. Place protective tape over the taper section of the No.2 fuel pipe's fuel pump to prevent damage.
      G07671517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.
    3. Install a NEW  O-ring, NEW  backup rings (No. 1 No. 2, and No. 3) and NEW  E-ring to the fuel injector as shown in the illustration.
      NOTE:
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
        G07671518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Check that the No. 3 fuel pipe installation end is not contaminated with foreign matter and is not damaged.
    4. Hand tighten the 2 stud bolts in the delivery pipe's bolt attachment holes. (torx® side up)
      G07671519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply gasoline to the No. 2 fuel pipe's O-ring and into the attachment hole of the delivery pipe's No. 3 fuel pipe.
    6. Press the fuel pipe and delivery pipe together by hand until there is no gap between them.
      NOTE:
      • Apply gasoline on both the O-ring and into the attachment hole. Lubricant will run out immediately after insertion if only applied to the O-ring side.
        G07671520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 stud bolts.
    8. Reinstall the 2 bolts but do not torque yet.
      G07671521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Turn the crankshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.
      NOTE: When installing the fuel pump by following the procedure described above: By not using the camshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No. 2 fuel pipe later.
    10. Pour 30 cc of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.
      G07671522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Apply a coat of engine oil to the pump activation cam and pump lifter part.
      G07671523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Install a NEW  fuel pump insulator to the cylinder head cover.
      NOTE:
      • Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.
        G07671524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Reinstall the fuel pump.
      NOTE: Do not apply excessive force to the heater hose and coolant pipe.
      G07671525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the Protective tape.
    15. Loosely install the No. 2 fuel pipe sub-assembly to the fuel pump assembly.
      NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
      G07671526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. Install the 2 nuts and tighten them in several passes.

      Torque Specification: 25 N.m (255 kgf.cm, 18 ft.lbf) 

      G07671527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. RECONNECT NO. 2 FUEL PIPE 
    1. Torque the 2 fuel pipe bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 19 mm union nut wrench, connect the fuel pipe.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

      G07671529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REINSTALL WATER HOSE JOINT (for IS350 2GR-FSE) 
    1. Reinstall the water hose joint with the 2 bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REINSTALL FUEL PRESSURE PULSATION DAMPER 
    1. Remove the protective tape and clean the attachment's surface.
    2. Once the 2 NEW  gaskets and fuel tube have been installed, attach the fuel pressure pulsation damper and tighten by hand.
    3. Use SST to securely tighten the pulsation damper.
    4. Connect the electrical connector to the fuel pump.
      G07671531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09617-24011 

      NOTE: Do not use pulsation dampers which have been dropped. Dropped dampers may not work properly.

      Torque Specification: 

      For Use With SST : 

      33 N.m (337 kgf.cm, 24 ft.lbf) 

      For Use Without SST : 

      40 N.m (408 kgf.cm, 30 ft.lbf) 

  8. REINSTALL NO. 1 FUEL PIPE 
    1. Reinstall the fuel pipe with the 2 bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

    2. Connect the 3 fuel hoses.
    3. Connect the ignition coil connector.
      G07671532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
F. IS350 2GR-FSE INTAKE MANIFOLD REINSTALLATION
G07671533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REINSTALL THE COMPONENTS SHOWN IN THE ILLUSTRATION ABOVE. Click link if additional assistance is required: 

  • IS350 2GR-FSE FUEL: FUEL INJECTOR (for Direct Injection): INSTALLATION (2007 IS350) 
G. IS250 4GR-FSE INTAKE MANIFOLD REINSTALLATION
G07671534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REINSTALL THE COMPONENTS SHOWN IN THE ILLUSTRATION ABOVE. Click link if additional assistance is required: 

  • IS250 4GR-FSE FUEL: FUEL INJECTOR: INSTALLATION (2007 IS250) 
F. CHECK FOR FUEL LEAKS & REASSEMBLY
  1. CONNECT THE NEGATIVE (-) BATTERY TERMINAL CABLE 
    G07671535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CHECK FOR FUEL LEAKS 
    1. Start and then stop the engine after approximately 5 seconds.
    2. Inspect each part for fuel leakage.
    3. If there is no fuel leakage found in step (b), restart the engine and re-inspect.
      NOTE:
      • Cranking alone may not start the high pressure fuel pump solenoid values used to produce fuel pressure (high pressure).
        G07671536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL ENGINE ROOM COVERS 
    G07671537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CHECK THROTTLE BODY 
    1. Check the throttle control motor operating sounds.
      1. Push the engine switch on.
      2. When pressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor. If friction noise exists, replace the throttle body.
    2. Check the throttle position sensor.
      1. Connect the techstream to the DLC3.
      2. Push the engine switch on.
      3. Depress the accelerator pedal. When the value is fully opened, check that the value of the "Throttle Sensor Position" is within the specification.

      Standard throttle valve opening percentage: 60? or more. 

      NOTE:
      • When checking the standard throttle valve opening percentage, the shift should be in the N position.
      • If the percentage is less than 60?, replace the throttle body.
  5. CHECK FOR DTC 
    1. If an error code displays, repair as necessary.
  6. TEST DRIVE 
    1. Test drive the vehicle and inspect for any abnormalities. (warning lamps, driveability, etc.)
  7. PERFORM INITIALIZATIONS 
    INITIALIZATION INFORMATION

    INITIALIZATION FUNCTION IS250 IS350
    Enter Recorded Presets Required Required
    Power Window Control System Required Required

VII. APPENDIX

A. CAMPAIGN PARTS DISPOSAL

As required by Federal Regulations, please make sure all campaign parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused.

TECHNICAL INSTRUCTIONS FOR SPECIAL SERVICE CAMPAIGN 9LA FUEL DELIVERY PIPE REPLACEMENT 2006-2007 GS300/350

G07671538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Revised January 26, 2011 

TECHNICAL INSTRUCTION REVISION NOTICE: 

I. OPERATION FLOW CHART

G07671539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

II. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE
AFFECTED VIN RANGE

Vehicle Model Year WMI VIN Range
VDS Range
GS300 2006 JTH BH96S 5000028 - 5045859
GS300 AWD 2006 CH96S 0001017 - 0021080
GS350 2007 JTH BE96S 0007608 - 0028362
GS350 AWD 2007 CE96S 0001838 - 0012689

III. PREPARATION

A. TOOLS
  • Standard hand tools
  • Torque wrench
  • 22 mm union nut wrench
  • SST: (non-essential) 09612-24014 (09617-24011)
  • SST: Stud Bolt - 04007-32331 (2 stud bolts have been included in each Service Manager's Package.)
  • SST: 09260-39015 Injector seal tool set. (02968-03020, 09268-03010) Lexus drawer 1
B. EQUIPMENT
  • Techstream
C. MATERIALS
  • Protective Tape
  • Wooden boards (for clamping purposes)
D. GS 300 PARTS
GS 300 PARTS INFORMATION

Model Part Number Part Description Qty
GS 300 04008-18331 Pipe Kit, Fuel Delivery, No. 3 1

The kit listed above includes the following parts: 

An illustration of the parts replaced and their installation location(s) have been provided. Please reference the tables below and on the next page.

KIT PARTS INFORMATION

Part Number Part Description Qty Illustration Installation Location(s)
17176-31020 Gasket (Air Surge Tank to Intake Manifold) 1
G07671540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 7
17177-31020 Gasket (No. 1 Intake Manifold to Head) 2
G07671541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 7
22271-31030 Gasket (Throttle Body) 1
G07671542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 7
23807-31020 Fuel Delivery Pipe 1
G07671543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23808-31010 No 2 Fuel Delivery Pipe 1
G07671544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
The parts listed below are packaged together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23915-46011 Fuel Pump Insulator 1
G07671545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
90301-06016 O-Ring 3
G07671546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
90301-06018 O-Ring 6
G07671547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90523-05007 E-Ring 9
G07671548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
The parts listed below are packaged together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23255-31010 Fuel Injector Seal 12
G07671549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
23256-74010 No.1 Fuel Injector Backup Ring 9
G07671550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23257-74010 No.2 Fuel Injector Backup Ring 9
G07671551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23258-28011 No.3 Fuel Injector Backup Ring (Flat) 9
G07671552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23279-74010 Gasket (Fuel Pressure Pulsation Damper) 2
G07671553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
23291-31011 Injector Vibration Insulator 6
G07671554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90430-08014 Gasket (Cold Start Injector) 2
G07671555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 7
90430-12026 Gasket 2
G07671556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10

Based upon the inspection results you may need to replace the fuel injectors. Please keep all fuel injectors for possible parts recovery and inspections. If requested you will need a fuel injector shipping kit for dealers. 

KIT PARTS INFORMATION

Model Part No. Insulator Color Part Name Qty/Unit
GS 300 23209-39057-A0(1) or Black Injector Assy, Fuel 6 (if needed)
23209-39057-B0(1) Reddish Brown
(1) Either injector listed for the vehicle type may be installed; however, make sure that all injectors installed on the vehicle are the same type. The injector may be identified by the injector insulator color. Please see page 31 for additional information.
E. GS 350 PARTS
GS 350 PARTS INFORMATION

Model Part Number Part Description Qty
GS 350 04008-18231 Pipe Kit, Fuel Delivery, No. 2 1

The kit listed above includes the following parts: 

An illustration of the parts replaced and their installation location(s) have been provided. Please reference the tables below and on the next page.

KIT PARTS INFORMATION

Part Number Part Description Qty Illustration Installation Location(s)
17176-31060 Gasket (Air Surge Tank to Intake Manifold) 1
G07671557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
17177-31060 Gasket (No. 1 Intake Manifold to Head) 2
G07671558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
22271-31020 Gasket (Throttle Body) 1
G07671559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
23807-31070 Fuel Delivery Pipe 1
G07671560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23808-31020 No 2 Fuel Delivery Pipe 1
G07671561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
The parts listed below are packaged together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23915-46011 Fuel Pump Insulator 1
G07671562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
90301-06016 O-Ring 3
G07671563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
90301-06018 O-Ring 6
G07671564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
23291-31011 Injector Vibration Insulator 6
G07671565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
The parts listed below are packaged together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23255-31010 Fuel Injector Seal 12
G07671566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
23256-74010 No.1 Fuel Injector Backup Ring 9
G07671567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23257-74010 No.2 Fuel Injector Backup Ring 9
G07671568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23258-28011 No.3 Fuel Injector Backup Ring (Flat) 9
G07671569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23279-74010 Gasket (Fuel Pressure Pulsation Damper) 2
G07671570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 9
90430-12026 Gasket 2
G07671571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 10
90523-05007 E-Ring 9
G07671572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10

Based upon the inspection results you may need to replace the fuel injectors. Please keep all fuel injectors for possible parts recovery and inspections. If requested you will need a fuel injector shipping kit for dealers. 

KIT PARTS INFORMATION

Model Part No. Insulator Color Part Name Qty/Unit
GS 350 23209-39155-B0(1) or Black Injector Assy, Fuel 6 (if needed)
23209-39155-C0(1) or Reddish Brown
23209-39155-D0(1) Green
(1) Either injector listed for the vehicle type may be installed; however, make sure that all injectors installed on the vehicle are the same type. The injector may be identified by the injector insulator color. Please see page 31 for additional information.
F. PARTS INSTALLATION LOCATION(S)
G07671573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

IV. WORK PROCEDURE TABLE OF CONTENTS

IMPORTANT: Only partial reinstallation steps are included in these Technical Instructions; please reference TIS for additional assistance if needed.

V. BACKGROUND

The involved vehicles are equipped with aluminum Fuel Delivery Pipes (Fuel Rails). Lexus has determined that ethanol fuels with a low moisture content will corrode the internal surface of the fuel rails. As this condition progresses, the engine Malfunction Indicator Light (MIL) may illuminate. Over time, the corrosion will create a pinhole resulting in fuel leakage.

G07671577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WORK PROCEDURE

VI. SAFETY PRECAUTIONS

A. PRECAUTIONS WHEN WORKING ON THE FUEL SYSTEM
IMPORTANT:
  • ALWAYS REMEMBER "SAFETY FIRST". 
  • IMMEDIATELY WIPE UP ANY SPILLED FUEL. 
  • BE EXTREMELY CAREFUL WHEN HANDLING FUEL TO PREVENT FIRES FROM OCCURRING. 
  • BEFORE REMOVING ANY FUEL SYSTEM PART, DRAIN ALL FUEL TO PREVENT SPILLING. 
  • BEFORE WORKING ON THE FUEL SYSTEM, PERFORM THE FOLLOWING SAFETY CHECK LIST. 
B. SAFETY CHECKLIST
  1. B. AIR VENTILATION 
    • Perform work in a well ventilated area.
    • DO NOT  work underground or in an area where fuel vapors may fill the room due to poor ventilation.
    • Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
    • Dry all cloths that have come in contact with fuel in a well ventilated area and dispose of them properly (according to applicable local regulations).
      G07671578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. C. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED 
    • Fires and ignition sources are prohibited while working on the fuel system.
    • Clearly display the sign found on the next page stating "WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES"  .
    • Smoking is prohibited near the work area.
    • DO NOT  work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
    • DO NOT  use work lamps or any other electrical appliance due to the risk of sparks flying from the power switch or a rise in temperature.
    • DO NOT  use metal hammers while working, due to the risk of flying sparks.
    • DO NOT  start any engine or perform any of the above in neighboring work bays.
      G07671579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. D. FIRE EXTINGUISHER 
    • Have a fire extinguisher ready and available before beginning work.
  4. E. PREVENT STATIC ELECTRICITY 
    • To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition.
    • Place appropriate warning cones or stand signs around the area as a caution.
      G07671580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07671581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07671582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. F. PRECAUTIONS WHEN USING A LIFT 
    • For bays equipped with auto lifts, cover all access cover joints with duct tape.
    • In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. Dissipate fuel vapors until the smell is gone.
      G07671583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. G. PREVENT THE FUEL FROM SPRAYING 
    • When disconnecting any fuel pipes or connectors there may still be some pressure remaining, even after discharging the system. To prevent the fuel from spraying, cover the pipe with a shop rag before disconnecting.
    • Remember to always wear protective goggles especially when disconnecting fuel pipes.
      G07671584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. H. PREVENT THE FUEL FROM CONTACTING OTHER PARTS 
    • Do not allow the fuel to come in contact with any parts made of rubber or leather.
      G07671585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. I. ASSIGN A SAFETY SUPERVISOR 
    • Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area.
  9. J. WORK SCHEDULING 
    • Work must be completed the same day.
    • As a general rule, do not stop work midway. If work must stop midway, inform your safety supervisor.
      G07671586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. K. WHEN CONNECTING THE FUEL PIPE 
    • Any amount of damage or small foreign object (dust, a piece of thread, rust, etc.) may cause a fuel leak. Be thorough when inspecting and cleaning the fuel pipes and seal surface areas.
      G07671587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

VII. FUEL DELIVERY PIPE REPLACEMENT

A. REMOVE THE ENGINE COVERS AND DISCHARGE THE FUEL SYSTEM
G07671588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. CHECK FOR DTCs 
    1. If DTC(s) are present, verify them, view and record the freeze frame data, and perform the necessary repairs.
  2. REMOVE THE ENGINE ROOM COVERS 
    • DO NOT DISCONNECT ANY PART OF THE FUEL SYSTEM UNTIL YOU HAVE DISCHARGED THE FUEL SYSTEM PRESSURE. 
    • EVEN AFTER DISCHARGING THE FUEL SYSTEM PRESSURE, PLACE A PIECE OF CLOTH AROUND THE FITTINGS AS YOU SEPARATE THEM TO REDUCE THE RISK OF FUEL SPRAYING ON YOURSELF, IN THE ENGINE COMPARTMENT, AND ONTO OTHER PARTS. 
  3. DISCHARGE THE FUEL SYSTEM PRESSURE 
    1. Remove the relay block upper cover No. 2.
    2. Remove the fuel pump (F/PMP) 25 amp fuse.
    3. Start the engine.
    4. After the engine has stopped, turn the ignition switch OFF.
    5. Crank the engine again to relieve any existing fuel pressure.
      NOTE: DTC P0171/25 and/or P0191/49 may be set.
    6. Remove the fuel cap to discharge the fuel tank pressure.
    7. Record the radio station presets.
      NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed after turning the ignition OFF.
    8. Disconnect the negative (-) battery cable.
    9. Reinstall the fuel pump (F/PMP) 25 amp fuse.
    10. Reinstall the relay block upper cover No. 2.
    11. Reinstall the fuel cap.
      G07671589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
B. REMOVE THE INTAKE MANIFOLD

GS300 (3GR-FSE) - INTAKE MANIFOLD REMOVAL 

GS350 (2GR-FSE) - INTAKE MANIFOLD REMOVAL 

  1. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
      NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
      G07671590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt, clip and inlet air cleaner.
      G07671591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 
    1. Disconnect the connector.
    2. Disconnect the No.2 ventilation hose.
      G07671592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the vacuum hose clamp.
      G07671593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Loosen the hose clamp bolt.
    5. Remove the 4 clips and air cleaner cap with air cleaner hose.
      G07671594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the 4 bolts and throttle with motor body assembly and gasket.
      G07671595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place protective tape over the surge tank opening to prevent foreign objects from entering from the old gasket above.
      G07671596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the connector.
    2. Disconnect the vacuum hose from the purge VSV.
      G07671597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the ventilation hose.
    4. Disconnect the union to check valve hose from the intake air surge tank.
    5. Disconnect the wire harness clamps from the intake air surge tank.
      G07671598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the 4 injector connectors.
    7. Disconnect the 3 wire harness clamps from the intake air surge tank.
    8. Disconnect the water by-pass hose from the intake air surge tank.
      G07671599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 bolts from the intake air surge tank, see illustration below.
      G07671600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a long hexagon 5 mm, remove the 6 bolts and using a 10mm remove the 2 nuts.
    11. Remove the intake surge tank and gasket.
      G07671601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Place protective tape over the intake manifold openings to prevent foreign objects from entering.
      G07671602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE INTAKE MANIFOLD 
    1. Pinch and pull the fuel tube connector to disconnect the connector from the delivery pipe.
      NOTE:
      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O- rings or cause leaks in the seal between the pipe and connector.
      • Do not use any tools to separate the pipe and connector.
      • Do not forcefully bend or twist the nylon tube.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
        G07671603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place and seal a plastic bag over the fuel tube to prevent damage or foreign objects from entering.
    3. Place protective tape around the sides of the pipe to prevent damage.
      G07671604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
      G07671605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place protective tape on the old gasket and place it over the cylinder head opening to prevent foreign objects from entering.
      G07671606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SKIP TO PAGE 25,  C. REMOVE FUEL DELIVERY PIPE 
GS300 (3GR-FSE) - INTAKE MANIFOLD REMOVAL
  1. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Remove the two nuts and V-bank cover.
      G07671607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt and air cleaner inlet.
      G07671608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 
    1. Disconnect the MAF connector.
    2. Disconnect the No. 2 Ventilation hose.
      G07671609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Disconnect the clamp.
    5. Disconnect the 2 fuel vapor feed hoses.
      G07671610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Loosen the hose clamp bolt.
    7. Remove the 4 clips and air cleaner cap with air cleaner hose.
      G07671611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the 4 bolts and throttle with motor body assembly and gasket.
      G07671612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place protective tape over the surge tank opening to prevent foreign objects from entering from the old gasket above.
      G07671613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the union to check valve hose from the intake air surge tank.
    2. Disconnect the wire harness and brake booster hose from the surge tank.
      G07671614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Remove the bolt and 2 gaskets, and disconnect the fuel tube from the cold start injector.
      NOTE: Do not fold or bend the hose.
      G07671615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the 2 clamps.
      G07671616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the connector.
      G07671617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the wire harness clamp from the intake air surge tank.
    8. Disconnect the water by-pass hose from the intake air surge tank.
    9. Remove the 4 bolts from the intake air surge tank, see illustration below.
      G07671618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07671619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a socket wrench hexagon 5 mm, remove the 7 bolts, and using a 10 mm socket remove the 2 nuts.
      G07671620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Disconnect the connector clamp from the intake air surge tank.
    12. Remove the bracket on the rear of the surge tank.
    13. Remove the intake air surge tank and gasket.
      G07671621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Place protective tape over the intake manifold openings to prevent foreign objects from entering.
      G07671622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE INTAKE MANIFOLD 
    1. Disconnect both SCV connectors.
    2. Remove the 4 bolts, 4 nuts, intake manifold and gasket.
    3. Place protective tape on the old gasket and place it over the cylinder head opening to prevent foreign objects from entering.
      G07671623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
C. REMOVE FUEL DELIVERY PIPE
  1. REMOVE NO. 1 FUEL PIPE 
    1. Disconnect the ignition coil connector illustrated.
    2. Disconnect the 3 fuel hoses.
    3. Remove the 2 bolts and No. 1 fuel pipe.
      NOTE:
      • Insert a hose plug into the hose.
        G07671624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Wipe away any spilt fuel with a shop rag.
  2. REMOVE FUEL PRESSURE PULSATION DAMPER 
    1. Disconnect the connector.
      NOTE: When the fuel pressure pulsation damper is removed, be certain to disconnect the connector to prevent it from being damaged by tools.
      G07671625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST or a 22 mm wrench, remove the fuel pressure pulsation damper and 2 gaskets from the fuel pump.

      SST 09617-24011 

      NOTE:
      • Do not blow pressurized air into the pulsation damper. The air pressure may damage the internal diaphragm.
        G07671626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place protective tape over the fuel pump and fuel tube to prevent damage.
      G07671627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE WATER HOSE JOINT (for GS350 2GR-FSE only) 
    1. Remove the 2 bolts and disconnect the water hose joint.
      G07671628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FUEL PUMP ASSEMBLY AND NO. 2 FUEL PIPE 
    IMPORTANT:

    WHEN REPLACING FUEL PIPE NO. 2, THE FUEL PUMP MUST BE REMOVED. THIS MUST BE DONE TO PREVENT SEAL DAMAGE AND THE TWISTING OF THE FUEL PIPE, FAILURE TO DO SO MAY RESULT IN A FUEL LEAK! 

    1. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.
      NOTE:
      • Must be absolutely no free play in the union on the fuel pump side.
      • If the union on the fuel pump side has free play, replace the fuel pump. 
        G07671629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts on the delivery pipe side.
      G07671630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts from the fuel pump.
      G07671631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel pump and fuel pump insulator.
      NOTE:
      • Wipe away any spilt fuel with a shop rag.
      • Do not apply excessive force to the heater hose and coolant pipe.
        G07671632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place protective tape on the old insulator and place it over the head cover opening to prevent foreign objects from entering.
      G07671633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 2 FUEL PIPE 
    1. Hand tighten the 2 SST stud bolts in the delivery pipe's bolt attachment holes. (torx® side up)

      SST 04007-32331 

      G07671634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel pipe from the fuel delivery pipe.
    3. Remove the 2 stud bolts.
      NOTE:
      • Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      • Fuel Pipes may be extremely tight, use caution while removing as to not cause damage.
        G07671635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. REMOVE NO. 3 FUEL PIPE 
      1. Remove the 4 bolts.
        G07671636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Hand tighten the 2 stud bolts to the delivery pipe. (torx® side up)
        NOTE: Attach the stud bolts diagonal from each other.
        G07671637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the fuel pipe from the fuel delivery pipe.
      4. Remove the 2 stud bolts.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 2 FUEL DELIVERY PIPE 

    To prevent possible injector damage, please proceed with the following steps in the order indicated.

    1. Disconnect the 3 wire harness clamps and remove the 2 bolts and 2 nuts.
    2. Remove the fuel delivery pipe.
    3. Disconnect the 3 electrical connectors by hand  .
      NOTE:
      • Do not exert extreme force while removing the fuel pipe, this may lead to injector damage.
      • Carefully move the fuel pipe back and forth from end to end while firmly pulling up will assist with removal.
      • Injectors may remain in the cylinder head during fuel pipe removal; if this occurs, carefully disconnect the electrical connector to prevent injector damage.
      • Be extremely careful not to touch or strike the tips of the injectors.
        G07671639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 injector vibration insulators from the cylinder head.
      G07671640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 1 FUEL DELIVERY PIPE 

    To prevent possible injector damage, please proceed with the following steps in the order indicated.

    1. Disconnect the fuel pressure sensor connector, wire harness clamps and remove the 2 bolts and 2 nuts.
    2. Lift the fuel delivery pipe up until it is horizontally level with the stud bolts.
    3. Carefully pull up on the front side of the fuel delivery pipe.
    4. Carefully pull the fuel delivery pipe up so that the fuel pressure sensor and the heater hose do not touch.
    5. Disconnect the 3 electrical connectors by hand  .
      NOTE:
      • Do not exert extreme force while removing the fuel pipe, this may lead to injector damage.
      • Carefully move the fuel pipe back and forth from end to end while firmly pulling up will assist with removal.
      • Injectors may remain in the cylinder head during fuel pipe removal; if this occurs, carefully disconnect the electrical connector to prevent injector damage.
      • Be extremely careful not to touch or strike the tips of the injectors.
      • To avoid damage to both components, do not allow the fuel pressure sensor to come in contact with the heater hose.
        G07671641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 injector vibration insulators from the cylinder head.
      G07671642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
D. REMOVE AND INSPECT FUEL INJECTORS
  1. REMOVE FUEL INJECTORS 
    1. Clamp the fuel injector assembly in a vise with wooden boards placed in between the vise and assembly.
      NOTE:
      • Be extremely careful not to touch or strike the tips of the injectors.
      • Use both hands when clamping the fuel injector assembly to the vise.
        G07671643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. With the fuel injector assembly clamped in the vise, remove the fuel delivery pipe by pulling straight back from the assembly as shown in the illustration.
      NOTE:
      • Clamp the vise to the areas illustrated on the fuel injector assembly. Do not clamp areas which are not indicated in the left illustration.
      • Do not over tighten. Also, do not allow the connector to come in contact with the vise.
        G07671644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nozzle holder clamp from the injectors.
      G07671645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: For reinstallation, attach a tag or label to the injector shaft.
      G07671646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Repeat steps a) ~ c) for the remaining injectors.
  2. FUEL INJECTOR INSPECTION 
    1. Inspect the condition of the fuel injector assembly as illustrated, and assess with the chart below.
      G07671647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CONDITION OF FUEL INJECTOR ASSEMBLY

      Condition of fuel injector assembly Results
      No white adhesion at entrance Reuse the fuel injector.
      White adhesion at entrance Replace ALL  fuel injectors with new ones. Keep used injectors for possible parts recovery and inspection.
      NOTE:
      • Either injector listed in the parts table for a particular vehicle type may be installed; however, make sure that all  injectors installed on the vehicle have the same color insulator.
      • GS300 23209-39057-A0 = Black
      • GS300 23209-39057-B0 = Reddish Brown
      • GS350 23209-39155-B0 = Black
      • GS350 23209-39155-C0 = Reddish Brown
      • GS350 23209-39155-D0 = Green
        G07671648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FUEL PRESSURE SENSOR 
    1. Clamp the No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Using a 24 mm wrench, remove the fuel pressure sensor and gasket.
      G07671649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL PRESSURE SENSOR 
    1. Clamp a NEW  No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Install a NEW  gasket to the fuel pressure sensor.
    3. Install the fuel pressure sensor to the No. 1 delivery pipe.
      G07671650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CALCULATE THE FUEL PRESSURE SENSOR TORQUE VALUE 
    IMPORTANT:
    • The calculated torque (C) is the value at which the torque wrench MUST be set. 
    • To determine the calculated torque, READ  , and CLOSELY follow the steps below. 
    • If using the formula L1 and L2 MUST be measured in feet. 
    1. Measure the length of the torque wrench from the center of the drive to the middle of the handle as shown in the illustration (L2)
    2. Determine the calculated torque (C) value to set the wrench to by referencing the table below.
      FUEL PRESSURE SENSOR TORQUE SPECIFICATIONS

      Torque Wrench Length - L2 (inches) Calculated Torque (ft lbs)
      10" 27.6
      12" 28.1
      14" 28.5
      16" 28.8
      18" 29
      20" 29.2
      NOTE: The torque wrench union nut MUST  be used when using the values in this table.

      Calculated Torque Formula: C= (T) x L2 / (L1 + L2) 

      LEGENDS REFERENCE CHART

      C Calculated Torque (ft.lbf)
      T Specified torque (ft.lbf) (31 ft.lbf)
      L1 Torque wrench adapter length or length of tool (ft.)
      L2 Length of torque wrench (ft.)
      G07671651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL RELIEF VALVE ASSY 
    1. Clamp the No. 2 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Using a 17 mm union nut wrench, remove the fuel relief valve and gasket.
      G07671652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL RELIEF VALVE ASSY 
    1. Clamp a NEW  No. 2 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Install a NEW  gasket to the fuel relief valve.
    3. Using union nut wrench 17 mm, install the fuel relief valve to the No. 2 delivery pipe.

      Torque Specification: 36 N.m (367 kgf.cm, 27 ft.lbf) 

      G07671653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL INJECTOR SEAL 
    1. Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.
    2. Repeat step a for the remaining injectors.
      NOTE: If an injector is dropped or the tips of the injectors are struck, replace it with a NEW  one.
  9. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the injector area shown in the illustration. Using a piece of cloth, clean carbon deposits from the injector and its grooves.
      NOTE:
      • Do not clean the tip of the injector.
      • Do not use a wire brush to clean the injector.
      • If an injector is dropped or the tips of the injectors are struck, replace it.
        G07671654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply engine oil to the injector contact surface of SST (guide). Then attach SST (guide) to the injector with the tapered inner portion facing the tip of the injector, as shown in the illustration.

      SST 09260-39015 (09268-03020, Guide) 

      NOTE: Due to the specific tolerances needed to seat the seals it will be difficult to slide the SST. Slowly wiggle it from side to side while sliding it up the injector little by little.
      G07671655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a NEW  injector seal to SST (holder).

      SST 09260-39015 (09268-03010, Holder) 

      NOTE: Be careful not to install the injector seal onto the SST (holder) at an angle. Doing so will stretch the seal.
      G07671656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install SST (holder with injector seal) to the tip of the injector. Slide the seal downward into the injector groove (injector connector side) with your fingers, as shown in the illustration.
    5. Using SST (holder), gently press downward on the injector seal (injector connector side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.
      NOTE:
      • Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.
      • When using SST (guide) to settle the seal into the groove, SST (guide) only needs to be slid upward to the position labeled A in the illustration.
      • After using SST (guide) to settle the seal into the groove, return SST (guide) to its position labeled B in the illustration.
        G07671657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install a NEW  injector seal to SST (holder).
      G07671658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install a NEW  injector seal to the injector groove (injector tip side) as shown in the illustration.
    8. Check that the seal covers the circumference of the injector groove as shown in the illustration.
      NOTE: Make sure that the seal does not slip into the welded groove of the injector shown in the illustration. If it does, replace it with a NEW  one.
      G07671659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.
      G07671660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using SST (holder), gently press downward on the injector seal (injector tip side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.
      NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.
    11. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.
      G07671661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. After installing the seals, check that the seal is not scratched, deformed or protruding from the injector groove.
      NOTE:
      • If the seal is scratched, deformed or protruding from the groove, replace it with a NEW  one.
      • The 2nd seal from the injector tip is partially on a tapered surface so after installation it may slide up to 0.5 mm.
    13. Repeat steps  a) ~  k), for the remaining injectors.
      G07671662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REPLACE FUEL INJECTOR O-RING, BACKUP RINGS AND E-RING 
    1. Remove the O-ring, backup rings and E-ring from the fuel injector.
    2. Install a NEW  O-ring, NEW  backup rings (No. 1, No. 2, No. 3) and NEW  E-ring to the fuel injector as shown in the illustration.
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
        G07671663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align and install the No.1 and No.2 back up rings to the fuel injector's tapered surface.
    3. Repeat steps a) ~ b), and install the 6 O-ring, NEW  backup rings (No. 1 No. 2, and No. 3) and NEW  E-ring.
      G07671664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FUEL INJECTOR ASSEMBLY 
    1. Install the injector nozzle holder clamp.
    2. Apply gasoline to the fuel injector's O-ring and into the attachment hole of the fuel delivery pipe.
      NOTE: Apply gasoline on both the O-ring and into the attachment hole. Lubricant will run out immediately after insertion if only applied to the O-ring side.
      G07671665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.
    4. Repeat steps a) ~ c) for the remaining injectors.
      NOTE:
      • Make sure that there is no gap between the delivery pipe and clamp.
        G07671666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
E. FUEL PIPE INSTALLATION
  1. INSTALL NO. 1 FUEL DELIVERY PIPE 
    1. Install 3 NEW  injector vibration insulators to the cylinder head.
    2. Apply lubricant to the installation hole of the injector.
      G07671667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While gently raising the front of the delivery pipe, carefully insert the fuel delivery pipe on to the cylinder head's stud bolts. Do not allow the fuel pressure sensor and heater hose come in contact.
      NOTE:
      • If an injector is dropped or the tips of the injectors are struck, replace it with a NEW  one.
      • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        G07671668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the delivery pipe's attachment holes with the stud bolts and install the delivery pipe without letting the fuel pressure sensor and heater hose come in contact.
    5. Connect the 3 electrical fuel injector connectors.
      G07671669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.
      G07671670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

    8. Connect the fuel pressure sensor connector and wire harness clamps.
      G07671671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 2 FUEL DELIVERY PIPE 
    1. Install 3 NEW  injector vibration insulators to the cylinder head.
    2. Apply lubricant to the installation holes of the injectors.
    3. Connect the 3 electrical connectors.
      G07671672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.
      NOTE:
      • If an injector is dropped or the tips of the injectors are struck, replace it with a NEW  one.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        G07671673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Reinstall the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

    6. Connect the 3 wire harness clamps.
      G07671674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REINSTALL NO. 3 FUEL PIPE 
    1. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.
    2. Install a NEW  O-ring, NEW  backup rings (No. 1 No. 2, and No. 3) and NEW  E-ring to the fuel injector as shown in the illustration.
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
        G07671675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align and install the No.1 and No.2 back up rings to the No. 3 fuel pipe's tapered surface.
      G07671676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Hand tighten the 2 stud bolts to the delivery pipe bolt attachment holes diagonally as illustrated. (torx® side up)
    4. Place protective tape over screw holes without stud bolts to prevent lubricant from entering.
    5. Apply gasoline to the No. 3 fuel pipe's O-ring and into the attachment hole of the delivery pipe's No. 3 fuel pipe.
      NOTE:
      • Failure to lubricate both o-ring and attachment hole, may damage the seal.
        G07671677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the protective tape and clean the delivery pipe attachment surface.
    7. Insert the 2 stud bolts through the No. 3 fuel pipe.
      G07671678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Press the fuel pipe and delivery pipe together by hand until there is no gap between them.
    9. Remove the 2 stud bolts once the pipes are together.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Clean the screw holes of dirt and gasoline, and then insert and tighten the 4 bolts in the order shown in the illustration.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 2 FUEL PIPE 
    IMPORTANT:

    WHEN REINSTALLING FUEL PIPE NO. 2 AND THE FUEL PUMP, FOLLOW THE TEMPORARY INSTALLATION, TIGHTENING AND OTHER PROCEDURES SHOWN TO PREVENT DAMAGE TO ALL SEALING SURFACES. 

    1. Place protective tape over the taper section of the No.2 fuel pipe's fuel pump to prevent damage.
      G07671681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.
    3. Install a NEW  O-ring, NEW  backup rings (No. 1 No. 2, and No. 3) and NEW  E-ring to the fuel injector as shown in the illustration.
      NOTE:
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
        G07671682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Check that the No. 3 fuel pipe installation end is not contaminated with foreign matter and is not damaged.
    4. Hand tighten the 2 stud bolts in the delivery pipe's bolt attachment holes. (torx® side up)
      G07671683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply gasoline to the No. 2 fuel pipe's O-ring and into the attachment hole of the delivery pipe's No. 3 fuel pipe.
    6. Press the fuel pipe and delivery pipe together by hand until there is no gap between them.
      NOTE:
      • Apply gasoline on both the O-ring and into the attachment hole. Lubricant will run out immediately after insertion if only applied to the O-ring side.
        G07671684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 stud bolts.
    8. Reinstall the 2 bolts but do not torque yet.
      G07671685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Turn the crankshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.
      NOTE: When installing the fuel pump by following the procedure described above: By not using the camshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No. 2 fuel pipe later.
    10. Pour 30 cc of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.
      G07671686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Apply a coat of engine oil to the pump activation cam and pump lifter part.
      G07671687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Install a NEW  fuel pump insulator to the cylinder head cover.
      NOTE:
      • Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.
        G07671688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Reinstall the fuel pump.
      NOTE: Do not apply excessive force to the heater hose and coolant pipe.
      G07671689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the Protective tape.
    15. Loosely install the No. 2 fuel pipe sub-assembly to the fuel pump assembly.
      NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
      G07671690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. Install the 2 nuts and tighten them in several passes.

      Torque Specification: 25 N.m (255 kgf.cm, 18 ft.lbf) 

      G07671691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. RECONNECT NO. 2 FUEL PIPE 
    1. Torque the 2 fuel pipe bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 19 mm union nut wrench, connect the fuel pipe.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

      G07671693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REINSTALL WATER HOSE JOINT (Step for GS350 2GR-FSE only) 
    1. Reinstall the water hose joint with the 2 bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REINSTALL FUEL PRESSURE PULSATION DAMPER 
    1. Remove the protective tape and clean the attachment's surface.
    2. Once the 2 NEW  gaskets and fuel tube have been installed, attach the fuel pressure pulsation damper and tighten by hand.
    3. Use SST or equivalent to securely tighten the pulsation damper.
    4. Connect the electrical connector to the fuel pump.
      G07671695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09617-24011 

      NOTE: Do not use pulsation dampers which have been dropped. Dropped dampers may not work properly.

      Torque Specification: 

      For Use With SST : 

      33 N.m (337 kgf.cm, 24 ft.lbf) 

      For Use Without SST : 

      40 N.m (408 kgf.cm, 30 ft.lbf) 

  8. REINSTALL NO. 1 FUEL PIPE 
    1. Reinstall the fuel pipe with the 2 bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

    2. Connect the 3 fuel hoses.
    3. Connect the ignition coil connector.
      G07671696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
F. GS350 2GR-FSE INTAKE MANIFOLD REINSTALLATION
G07671697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REINSTALL THE COMPONENTS SHOWN IN THE ILLUSTRATION ABOVE. Click link if additional assistance is required: 

  • GS350 2GR-FSE FUEL: FUEL INJECTOR (for Direct Injection): INSTALLATION (2007 GS350) 
G. GS300 3GR-FSE INTAKE MANIFOLD REINSTALLATION
G07671698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REINSTALL THE COMPONENTS SHOWN IN THE ILLUSTRATION ABOVE. Click link if additional assistance is required: 

  • GS300 3GR-FSE FUEL: FUEL INJECTOR: INSTALLATION (2006 GS300) 
H. CHECK FOR FUEL LEAKS & REASSEMBLY
  1. CONNECT THE NEGATIVE (-) BATTERY TERMINAL CABLE 
    G07671699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CHECK FOR FUEL LEAKS 
    1. Start and then stop the engine after approximately 5 seconds.
    2. Inspect each part for fuel leakage.
    3. If there is no fuel leakage found in step (b), restart the engine and re-inspect.
      NOTE:
      • Prepare for fuel leakage. Next, start the engine and stop it approximately 5 seconds later. Inspect for fuel leakage.
        G07671700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Cranking alone may not start the high pressure fuel pump solenoid values used to produce fuel pressure (high pressure).
  3. REINSTALL ENGINE ROOM COVERS 
    G07671701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CHECK THROTTLE BODY 
    1. Check the throttle control motor operating sounds.
      1. Push the engine switch on.
      2. When pressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor. If friction noise exists, replace the throttle body.
    2. Check the throttle position sensor.
      1. Connect the techstream to the DLC3.
      2. Push the engine switch on.
      3. Depress the accelerator pedal. When the value is fully opened, check that the value of the "Throttle Sensor Position" is within the specification.

      Standard throttle valve opening percentage: 60? or more. 

      NOTE:
      • When checking the standard throttle valve opening percentage, the shift should be in the N position.
      • If the percentage is less than 60?, replace the throttle body.
  5. CHECK FOR DTC 
    1. If an error code displays, repair as necessary.
  6. TEST DRIVE 
    1. Test drive the vehicle and inspect for any abnormalities. (warning lamps, driveability, etc.)
  7. PERFORM INITIALIZATIONS 
    INITIALIZATION FUNCTION

    INITIALIZATION FUNCTION GS300 GS350
    Enter Recorded Presets Required Required
    Power Window Control System Required Required
    Sliding Roof System Required  
    Clearance Sonar System Required  
    Variable Gear Ratio Steering System Required Required
    Intuitive Parking Assist System   Required

VIII. APPENDIX

A. CAMPAIGN PARTS DISPOSAL

As required by Federal Regulations, please make sure all campaign parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused.

TECHNICAL INSTRUCTIONS FOR SPECIAL SERVICE CAMPAIGN 9LA FUEL DELIVERY PIPE REPLACEMENT 2007 - 2008 LS460/LS460L

G07671702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Revised January 26, 2011 

TECHNICAL INSTRUCTION REVISION NOTICE: 

I. OPERATION FLOW CHART

G07671703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

II. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE
AFFECTED VIN RANGE

Vehicle Model Year WMI VIN Range
VDS Range
LS460 2007 JTH BL46F 5000133 - 5051857
2008 5051858 - 5055333
LS460L 2007 GL46F 5000112 - 5020667
2008 5020680 - 5021639

III. PREPARATION

A. TOOLS
  • Standard hand tools
  • Torque wrench
  • 22 mm union nut wrench
  • SST: (non-essential) 09612-24014 (09617-24011)
  • SST: Stud Bolt - 04007-32331 (2 stud bolts have been included in each Service Manager's Package.)
  • SST: 09260-39015 Injector seal tool set. (02968-03020, 09268-03010) Lexus drawer 1
B. EQUIPMENT
  • Techstream
  • Radiator Cap Tester
C. MATERIALS
  • Protective Tape
  • Coolant (Toyota SLLC P/N 00272-SLLC2 or equivalent)
  • Wooden boards (for clamping purposes)
D. PARTS
PARTS INFORMATION

Part Number Part Description Qty
04008-18138 Pipe Kit, Fuel delivery, No. 1 1

The kit listed above includes the following parts: 

An illustration of the parts replaced and their installation location(s) have been provided. Please reference the tables below and on the next two pages.

KIT PARTS INFORMATION

Part Number Part Description Qty Illustration Installation Location(s)
17171-38020 Gasket (No. 1 Intake Manifold to Head) 2
G07671704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 6
22271-50050 Gasket (Throttle Body) 1
G07671705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 6
23814-38051 Fuel Delivery Pipe 1
G07671706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 8 & 9
23815-38031 No 2 Fuel Delivery Pipe 1
G07671707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 8 & 10
The parts listed below are packaged together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
16418-20290 Radiator Drain Packing 1
G07671708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 N/A
16492-21050 Radiator O-Ring 1
G07671709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 N/A
23255-31010 Fuel Injector Seal 16
G07671710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23256-38010 No.1 Fuel Pipe Backup Ring 4
G07671711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 8, 9 & 10
23256-74010 No.1 Fuel Injector Backup Ring 8
G07671712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23257-38010 No. 2 Fuel Pipe Backup Ring 4
G07671713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 8, 9 & 10
23257-74010 No.2 Fuel Injector Backup Ring 8
G07671714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
90301-06019 O-Ring 4
G07671715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 8, 9 & 10
The parts listed below are packaged together in a clear plastic bag.
Part Number Part Description Qty Illustration Installation Location(s)
23258-28011 No.3 Fuel Injector Backup Ring (Flat) 8
G07671716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
23279-74010 Gasket (Fuel Pressure Pulsation Damper) 4
G07671717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 7
23291-31011 Injector Vibration Insulator 8
G07671718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Page 8
90301-06018 O-Ring 8
G07671719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
90430-12026 Gasket 4
G07671720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10
90523-04006 E-Ring 4
G07671721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 8, 9 & 10
90523-05007 E-Ring 8
G07671722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 See Pages 9 & 10

Based upon the inspection results you may need to replace the fuel injectors. Please keep all fuel injectors for possible parts recovery and inspections. If requested you will need a fuel injector shipping kit for dealers. 

KIT PARTS INFORMATION

Model Part No. Insulator Color Part Name Qty/Unit
LS460/LS460L 23209-39155-B0(1) or Black Injector Assy, Fuel 8 (as needed)
23209-39155-C0(1) or Reddish Brown
23209-39155-D0(1) Green
(1) Either injector listed for the vehicle type may be installed; however, make sure that all  injectors installed on the vehicle are the same type. The injector may be identified by the injector insulator color. Please see page 32 for addition information.
E. PARTS INSTALLATION LOCATION(S)
G07671723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07671727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

IV. TABLE OF CONTENTS

IMPORTANT: Only partial reinstallation steps are included in these Technical Instructions; please reference TIS for additional assistance if needed.

V. BACKGROUND

The involved vehicles are equipped with aluminum Fuel Delivery Pipes (Fuel Rails). Lexus has determined that ethanol fuels with a low moisture content will corrode the internal surface of the fuel rails. As this condition progresses, the engine Malfunction Indicator Light (MIL) may illuminate. Over time, the corrosion will create a pinhole resulting in fuel leakage.

G07671728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WORK PROCEDURE

VI. SAFETY PRECAUTIONS

A. PRECAUTIONS WHEN WORKING ON THE FUEL SYSTEM
IMPORTANT:
  • ALWAYS REMEMBER "SAFETY FIRST". 
  • IMMEDIATELY WIPE UP ANY SPILT FUEL. 
  • BE EXTREMELY CAREFUL WHEN HANDLING FUEL TO PREVENT FIRES FROM OCCURRING. 
  • BEFORE REMOVING ANY FUEL SYSTEM PART, DRAIN ALL FUEL TO PREVENT SPILLING. 
  • BEFORE WORKING ON THE FUEL SYSTEM, PERFORM THE FOLLOWING SAFETY CHECK LIST. 
B. SAFETY CHECKLIST
  1. AIR VENTILATION 
    • Perform work in a well ventilated area.
    • DO NOT  work underground or in an area where fuel vapors may fill the room due to poor ventilation.
    • Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
    • Dry all cloths that have come in contact with fuel in a well ventilated area and dispose of them properly (according to applicable local regulations).
      G07671729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED 
    • Fires and ignition sources are prohibited while working on the fuel system.
    • Clearly display the sign found on the next page stating "WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES". 
    • Smoking is prohibited near the work area.
    • DO NOT  work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
    • DO NOT  use work lamps or any other electrical appliance due to the risk of sparks flying from the power switch or a rise in temperature.
    • DO NOT  use metal hammers while working, due to the risk of flying sparks.
    • DO NOT  start any engine or perform any of the above in neighboring work bays.
      G07671730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. FIRE EXTINGUISHER 
    • Have a fire extinguisher ready and available before beginning work.
  4. PREVENT STATIC ELECTRICITY 
    • To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition.
    • Place appropriate warning cones or stand signs around the area as a caution.
      G07671731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07671732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07671733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. PRECAUTIONS WHEN USING A LIFT 
    • For bays equipped with auto lifts, cover all access cover joints with duct tape.
    • In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. Dissipate fuel vapors until the smell is gone.
      G07671734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. PREVENT THE FUEL FROM SPRAYING 
    • When disconnecting any fuel pipes or connectors there may still be some pressure remaining, even after discharging the system. To prevent the fuel from spraying, cover the pipe with a shop rag before disconnecting.
    • Remember to always wear protective goggles especially when disconnecting fuel pipes.
      G07671735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS 
    • Do not allow the fuel to come in contact with any parts made of rubber or leather.
      G07671736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. ASSIGN A SAFETY SUPERVISOR 
    • Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area.
  9. WORK SCHEDULING 
    • Work must be completed the same day.
    • As a general rule, do not stop work midway. If work must stop midway, inform your safety supervisor.
      G07671737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. WHEN CONNECTING THE FUEL PIPE 
    • Any amount of damage or small foreign object (dust, a piece of thread, rust, etc.) may cause a fuel leak. Be thorough when inspecting and cleaning the fuel pipes and seal surface areas.
      G07671738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

VII. FUEL DELIVERY PIPE REPLACEMENT

A. REMOVE THE ENGINE COVERS AND DISCHARGE THE FUEL SYSTEM
G07671739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. DTC CHECK 
    1. If DTC(s) are present, verify them, view and record the freeze frame data, and perform the necessary repairs.
  2. REMOVE THE ENGINE ROOM COVERS 
    • DO NOT DISCONNECT ANY PART OF THE FUEL SYSTEM UNTIL YOU HAVE DISCHARGED THE FUEL SYSTEM PRESSURE. 
    • EVEN AFTER DISCHARGING THE FUEL SYSTEM PRESSURE, PLACE A PIECE OF CLOTH AROUND THE FITTINGS AS YOU SEPARATE THEM TO REDUCE THE RISK OF FUEL SPRAYING ON YOURSELF, IN THE ENGINE COMPARTMENT, AND ONTO OTHER PARTS. 
  3. DISCHARGE THE FUEL SYSTEM PRESSURE 
    1. Remove the relay block upper cover No. 2.
    2. Remove the circuit opening relay.
    3. Start the engine.
    4. After the engine has stopped, turn the ignition switch off.
    5. Crank the engine again to relieve any existing fuel pressure.
      NOTE: DTC P0171/25 and/or P0191/49 may be set.
    6. Fully remove the fuel cap to discharge the fuel tank pressure and then reinstall cap.
    7. Record the radio station presets.
      NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed. The HDD navigation system requires approximately 6 minutes to save memory and settings, after turning OFF the ignition.
      G07671740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the negative (-) battery cable.
    9. Reinstall the circuit opening relay and relay block upper cover No. 2.
B. REMOVE FUEL DELIVERY PIPE WITH FUEL INJECTOR
  1. REMOVE BATTERY 
    G07671741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Pull up on the rear of the V-bank cover until the clips release.
    2. Slide the V-bank cover sub-assembly towards the front of the vehicle to unhook the 2 claws.
      NOTE: Do not lift the cover's front and back end together, as this may damage the claws.
      G07671742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO.1 AIR CLEANER INLET 
    1. Remove the 2 bolts located on the radiator support.
    2. For both the left and right sides, pull on protrusions A and B and then disconnect the 4 outer claws.
    3. Remove No. 1 air cleaner inlet without disconnecting the inner left and right 2 claws for protrusion C.
      NOTE: When removing the No. 1 air cleaner inlet, gently pull inwards to prevent damage.
      G07671743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DRAIN ENGINE COOLANT 
    1. Loosen the radiator drain plug and drain coolant.
    2. Remove plug and o-ring.
    3. Remove the radiator reservoir cap.
    4. Dispose coolant according to local regulations.
      NOTE: Wait until engine coolant temperature has dropped significantly before releasing pressurized coolant. Hot coolant may cause serious injuries or burns.
      G07671744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE INTAKE AIR CONNECTOR PIPE 
    1. Remove the clamp, and disconnect the wire harness.
      G07671745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 ventilation hoses.
      G07671746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Loosen the 3 hose clamps, and remove the intake air connector pipe.
      G07671747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE AIR CLEANER ASSEMBLIES (LH SHOWN) 
    1. Disconnect the MAF meter connector.
    2. Disconnect the 2 clamps, and air cleaner cap, then remove the air filter.
      G07671748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts, clip and air cleaner case LH.
    4. Repeat steps a) through c) for the RH side.
      G07671749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY 
    1. Disconnect the 2 water by-pass hoses.
      G07671750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the throttle motor connector.
    3. Remove the 4 bolts, throttle with motor body assembly and gasket.
      G07671751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place protective tape over the throttle with motor body assembly openings.
    5. Place protective tape over the surge tank opening.
      G07671752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT ENGINE WIRE 
    1. Remove the bolt, and disconnect the 3 clamps.
    2. Disconnect the clamp and connector.
    3. Remove the 2 bolts, and disconnect the 3 clamps and 3 connectors.
      G07671753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      See illustration below for steps d) ~ j) 

    4. Remove the engine room ECU outlet duct.
    5. Remove the 3 bolts and ECM box cover (upper).
    6. Disconnect the 3 ECT and 4 ECM connectors.
    7. Disconnect the 3 connectors.
    8. Remove the box cover (upper).
    9. Disconnect the 3 connectors and clamp.
    10. Disconnect the engine wire harness.
      G07671754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the box cover (upper).
    12. Remove the nut, and disconnect the 2 clamps and wire harness.
      G07671755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the 3 bolts, and disconnect the 3 clamps.
    14. Disconnect the 23 connectors.
    15. Disconnect the engine wire harness.
      G07671756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. Disconnect the 8 injector driver connectors as shown in the illustration.
      G07671757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Remove the 4 nuts, and disconnect the engine wire.
      G07671758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 VENTILATION HOSE 
    G07671759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 2 VENTILATION HOSE 
    G07671760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE INJECTOR DRIVER 
    1. Using a deep 10mm socket wrench, remove the 2 bolts and 2 nuts.
    2. Disconnect the 3 clamps, and remove the injector driver.
      G07671761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 ENGINE COVER 
    G07671762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Disconnect the 2 heater water hoses.
    2. Remove the 2 bolts, and disconnect the water by-pass pipe sub-assembly.
      G07671763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT PURGE VSV 
    1. Disconnect the purge VSV hose.
    2. Remove the bolt, and disconnect the purge VSV.
      G07671764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE INTAKE MANIFOLD 
    1. Disconnect the ventilation hose.
      G07671765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt located on the back of the intake manifold.
      G07671766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a 12 mm deep socket wrench, remove the 8 bolts and 2 nuts.
      G07671767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Lift the engine wire harness towards yourself.
    5. Gather up the disconnected connectors of the engine wire harness and have an assistant lift the harness.
    6. With the harness raised, lift the intake manifold and disengage it from the studs. Then slide the front of the manifold towards the right bank.
    7. Remove the intake manifold from the right bank.
    8. Remove the 2 gaskets.
      G07671768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Place protective tape over the intake manifold openings to prevent foreign objects from entering.
      G07671769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 3 ENGINE COVER SUB-ASSEMBLY 
    1. Disconnect the clamp.
      G07671770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, and disconnect the bracket.
      NOTE: Do not disconnect the bolt connected to the cable.
      G07671771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 clips and No. 3 engine cover subassembly.
      G07671772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE ENGINE COVER SUB-ASSEMBLY 
    1. Remove the 3 engine covers.
      G07671773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 19 mm union nut wrench, remove the No. 4 fuel pipe sub-assembly.
      G07671774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE PCV HOSE 
    G07671775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 3 FUEL HOSE 
    1. Remove the fuel pipe clamp.
    2. Pinch and pull the fuel hose connector to disconnect the connector from the delivery pipe.
    3. Cover the pipe and connector ends to prevent damage and dirt contamination.
      NOTE:
      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
      • Do not use any tools to separate the pipe and connector.
      • Do not forcefully bend or twist the nylon tube.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
        G07671776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place and seal a plastic bag over the fuel tube to prevent damage or foreign objects from entering.
    5. Place protective tape around the sides of the pipe to prevent damage.
      G07671777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Remove the bolt and bracket.
      G07671778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 3 fuel hoses illustrated.
      G07671779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST or equivalent, remove the fuel pressure pulsation damper LH and 2 gaskets from the fuel pump.

      SST 09612-24014 (09617-24011) 

      NOTE:
      • When the gasket is attached, do not attempt to forcefully twist and remove the damper. Doing so may damage the seal surface.
      • Do not blow air into the pulsation damper. The air pressure may damage the internal diaphragm.
        G07671780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST or equivalent, remove the fuel pressure pulsation damper RH and 2 gaskets from the fuel pump.

      SST 09612-24014 (09617-24011) 

      NOTE:
      • When the fuel pressure pulsation damper is removed, be careful not to let the fuel pump's return pipe from interfering.
      • Do not blow air into the pulsation damper. The air pressure may damage the internal diaphragm.
        G07671781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt from the LH side of the engine bay.
      G07671782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt, and disconnect the No.1 fuel pipe sub-assembly.
      NOTE: Wipe away any spilt fuel with a shop rag.
      G07671783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY 
    1. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.
      NOTE:
      • There must be absolutely no free play in the union on the fuel pump side.
      • If the union on the fuel pump side has free play, replace the fuel pump  .
        G07671784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts.
      G07671785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach 2 stud bolts to the delivery pipe bolt attachment holes and hand tighten. (torx® side up)
      G07671786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel pipe from the fuel delivery pipe.
    5. Remove the 2 stud bolts.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY 
    1. Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.
      NOTE:
      • Must be absolutely no free play in the union on the fuel pump side.
      • If the union on the fuel pump side has free play, replace the fuel pump  .
        G07671788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts illustrated.
      G07671789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach 2 stud bolts to the delivery pipe bolt attachment holes and hand tighten. (torx® side up)
      G07671790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel pipe from the fuel delivery pipe.
    5. Remove the 2 stud bolts.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL DELIVERY PIPES 
    1. Disconnect the fuel pressure sensor connector from the No. 2 fuel delivery pipe.
      G07671792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 electrical injector connectors.
      G07671793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 5 bolts and delivery pipe.
      NOTE:
      • Be extremely careful not to touch or strike the tips of the injectors.
        G07671794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Pull and remove the fuel delivery pipe in a straight line without tilting it.
    4. Remove the 4 injector vibration insulators.
    5. Repeat steps b) ~ d) for the No. 1 fuel delivery pipe.
      G07671795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
C. REPLACE FUEL DELIVERY PIPE
  1. REMOVE FUEL INJECTOR ASSEMBLY 
    1. With the No. 1 and No. 2 fuel delivery pipes still attached, clamp the fuel injector assembly in a vise with wooden boards placed in between the vise and assembly.
    2. Remove the fuel injector by pulling straight up.
      NOTE:
      • Be extremely careful not to touch or strike the tips of the injectors.
        G07671796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Clamp the vise to the areas illustrated on the fuel injector assembly. Do not clamp areas which are not indicated in the left illustration.
      • Use both hands when clamping the fuel injector assembly to the vise.
      • Do not over tighten. Also, do not allow the connector to come in contact with the vise.
        G07671797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nozzle holder clamp from the injectors.
      G07671798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Repeat steps a) ~ c) for the remaining injectors.
      NOTE: For reinstallation, attach a tag or label to the injector shaft.
      G07671799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. FUEL INJECTOR INSPECTION 
    1. Inspect the condition of the fuel injector assembly as illustrated, and assess with the chart below.
      G07671800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CONDITION OF FUEL INJECTOR ASSEMBLY

      Condition of fuel injector assembly Results
      No white adhesion at entrance Reuse the fuel injector.
      White adhesion at entrance Replace ALL  fuel injectors with new ones. Keep used injectors for possible parts recovery and inspection.
      NOTE:
      • Either injector listed in the parts table for a particular vehicle type may be installed; however, make sure that all  injectors installed on the vehicle have the same color insulator.
      • -B0 = Black insulator color
      • -C0 = Reddish brown insulator color
      • -D0 = Green insulator color
        G07671801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FUEL DELIVERY PIPE PLUGS 
    1. Clamp the No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Using a socket hexagon wrench 6mm, remove the fuel delivery pipe plug and gasket.
    3. Repeat steps a) ~ b) for the No. 2 fuel delivery pipe.
      G07671802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL DELIVERY PIPE PLUGS 
    1. Clamp a NEW  No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise
    2. Install a NEW  gasket to the fuel relief valve.
    3. Repeat steps a) ~ b), for the No. 2 fuel delivery pipe.

      Torque Specification: 38 N.m (388 kgf.cm, 28 ft.lbf) 

      G07671803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FUEL PIPE SUPPORTS. 
    1. Clamp the No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Using a 10mm deep socket wrench, remove the 2 bolts.
      G07671804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Hand tighten the 2 stud bolts to the delivery pipe bolt attachment holes. (torx® side up)
    4. Remove the fuel delivery pipe support.
    5. Remove the 2 stud bolts.
    6. Repeat steps a) ~ b) and remove the No. 2 fuel delivery pipe supports.
      NOTE:
      • Shifting the fuel pipe support too widely may damage the part which may lead to a fuel leak
        G07671805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL PIPE SUPPORT 
    1. Remove the O-ring, backup rings and E-ring from the fuel pipe support.
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 fuel pipe rings, o-ring and backup ring are installed in the correct direction and order.
      • Check that the alignment openings of the fuel pipe rings are not overlapped or stretched.
        G07671806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a NEW  O-ring, NEW  backup rings (No. 1 and No. 2) and NEW  E-ring to the fuel pipe support as illustrated.
      NOTE: Align and install the No.1 and No.2 backup rings to the fuel pipe support tapered surface.
      G07671807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clamp a NEW  No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    4. Hand tighten 2 stud bolts to the delivery pipe bolt attachment holes. (torx® side up)
    5. Apply gasoline to the fuel pipe support's O-ring and into the attachment hole of the delivery pipe's fuel pipe support.
    6. Press the fuel pipe support and delivery pipe together by hand until there is no gap between them.
    7. Remove the 2 stud bolts.
      G07671808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not over apply lubricant.
      • Apply gasoline on both the O-ring and into the attachment hole. The gasoline will run out immediately after insertion if only applied to the O-ring side.
    8. Using a 10mm deep socket wrench, install the 2 bolts.
    9. Repeat steps a) ~ h), for the No. 2 fuel delivery pipe.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL RELIEF VALVE ASSY 
    1. Clamp the No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise.
    2. Using a 17mm deep socket wrench, remove the fuel relief valve and gasket.
      G07671810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL RELIEF VALVE ASSY 
    1. Clamp a NEW  No. 1 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Install a NEW  gasket to the fuel relief valve.
    3. Using a 17mm deep socket wrench, install the fuel relief valve assembly.

      Torque Specification: 40 N.m (408 kgf.cm, 30 ft.lbf) 

      G07671811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL PRESSURE SENSOR 
    1. Clamp the No. 2 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise.
    2. Remove the fuel pressure sensor and gasket.
  9. INSTALL FUEL PRESSURE SENSOR 
    1. Clamp a NEW  No. 2 fuel delivery pipe in a vise with wooden boards placed in between the pipe and vise as illustrated.
    2. Install a NEW  gasket to the fuel pressure sensor.
    3. Install the fuel pressure sensor to the No. 1 delivery pipe and torque to specification.
      G07671812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CALCULATE THE FUEL PRESSURE SENSOR TORQUE VALUE 
    IMPORTANT:
    • The calculated torque (C) is the value at which the torque wrench MUST be set. 
    • To determine the calculated torque, READ  , and CLOSELY follow the steps below. 
    • If using the formula L1 and L2 MUST be measured in feet. 
    1. Measure the length of the torque wrench from the center of the drive to the middle of the handle as shown in the illustration (L2)
    2. Determine the calculated torque (C) value to set the wrench to by referencing the table below.
      FUEL PRESSURE SENSOR TORQUE SPECIFICATIONS

      Torque Wrench Length - L2 (inches) Calculated Torque (ft lbs)
      10" 27.6
      12" 28.1
      14" 28.5
      16" 28.8
      18" 29
      20" 29.2
      NOTE: The torque wrench union nut MUST  be used when using the values in this table.

      Calculated Torque Formula: C= (T) x L2 / (L1 + L2) 

      LEGENDS REFERENCE CHART

      C Calculated Torque (ft.lbf)
      T Specified torque (ft.lbf) (31 ft.lbf)
      L1 Torque wrench adapter length or length of tool (ft.)
      L2 Length of torque wrench (ft.)
      G07671813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL INJECTOR SEAL 
    1. Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.
    2. Repeat step a for the remaining injectors.
      NOTE: If an injector is dropped or the tips of the injectors are struck, replace it with a NEW one.
      G07671814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FUEL INJECTOR SEAL 
    1. Using a piece of cloth and engine conditioner, clean carbon deposits from the injector and its grooves.
      NOTE:
      • Do not clean the tip of the injector.
      • Do not clean with a wire brush.
      • If an injector is dropped or the tips of the injectors are struck, replace it.
    2. Apply engine oil to the injector contact surface of SST (guide). Then attach SST (guide) to the injector with the tapered inner portion facing the tip of the injector, as shown in the illustration.

      SST 09260-39015 (09268-03020, guide) 

      NOTE: Due to the specific tolerances needed to seat the seals it will be difficult to slide the SST. Slowly wiggle it from side to side while sliding it up the injector little by little.
      G07671815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a NEW  injector seal to SST (holder).

      SST 09260-39015 (09268-03010, holder) 

      NOTE: Be careful not to install the injector seal to the SST (holder) at an angle. Doing so will stretch the seal.
      G07671816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install SST (holder with injector seal) to the tip of the injector. Slide the seal downward into the injector groove (injector connector side) with your fingers, as shown in the illustration.
      G07671817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST (holder), gently press downward on the injector seal (injector connector side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.
      NOTE:
      • Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.
      • When using SST (guide) to settle the seal into the groove, SST (guide) only needs to be slid upward to the position labeled A in the illustration.
      • After using SST (guide) to settle the seal into the groove, return SST (guide) to its position labeled B in the illustration.
        G07671818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install a NEW  injector seal to SST (holder).
      G07671819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install a NEW  injector seal to the injector groove (injector tip side) as shown in the illustration.
    8. Check that the seal covers the circumference of the injector groove as shown in the illustration.
      NOTE: Make sure that the seal does not slip into the welded groove of the injector shown in the illustration. If it does, replace it with a NEW  seal.
      G07671820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector connector side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.
      G07671821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using SST (holder), gently press downward on the injector seal (injector tip side). Then slowly slide SST (guide) towards the injector tip to settle the seal into the injector groove.
      NOTE: Be careful that the seal is not pinched between SST (guide) and the injector groove. Replace the seal if it becomes damaged.
      G07671822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Slowly slide SST (guide) towards the tip of the injector. When the injector contact surface of SST (guide) aligns with the seal (injector tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the seal into the injector groove.
    12. After installing the seals, check that the seal is not scratched, deformed or protruding from the injector groove, if the seal is damaged, replace it with a new one  .
      NOTE:
      • The second seal from the injector tip is next to a tapered surface so after installation it may slide up to 0.5 mm.
    13. Repeat steps  a) ~  l), for the remaining injectors.
      G07671823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REPLACE FUEL INJECTOR O-RING, BACKUP RINGS AND E-RING 
    1. Remove the O-ring, backup rings and E-ring from the fuel injector.
    2. Install a NEW  O-ring, NEW  backup rings (No. 1, No. 2, No. 3) and NEW  E-ring to the fuel injector as shown in the illustration.
      NOTE:
      • Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
        G07671824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align and install the No.1 and No.2 backup rings to the fuel injector's tapered surface.
    3. Repeat steps a) ~ b), and install the 8 NEW  O-ringS, NEW  backup rings (No. 1 No. 2, and No. 3) and NEW  E-rings.
  14. INSTALL FUEL INJECTOR ASSEMBLY 
  1. Install the injector nozzle holder clamp.
  2. Apply gasoline to the fuel injector's O-ring and into the attachment hole of the fuel delivery pipe.
    NOTE: Apply gasoline on both the O-ring and into the attachment hole. The gasoline will run out immediately after insertion if only applied to the O-ring side.
    G07671825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.
  4. Repeat steps a) ~ c) for the remaining injectors.
    NOTE:
    • Make sure that there is no gap between the delivery pipe and clamp.
    • Check that there is no foreign matter or damage to the injector insertion hole of the delivery pipe.
      G07671826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
D. INSTALL FUEL DELIVERY PIPE WITH FUEL INJECTOR
  1. INSTALL FUEL DELIVERY PIPES 
    1. Install 4 NEW  injector vibration insulators.
    2. Apply lubricant to the installation injector seal and holes of the cylinder head.
      G07671827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No. 1 delivery pipe with the 5 bolts.

      Torque Specification: 21 N.m (214 kgf.cm, 15 ft.lbf) 

      NOTE:
      • If an injector is dropped or the tips of the injectors are struck, replace it with a NEW  one.
      • Check that there is no foreign matter or damage to the injector insertion hole of the cylinder head.
      • When inserting the fuel delivery pipe, push it in evenly without tilting it.
        G07671828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 4 injector connectors.
    5. Repeat steps a) ~ d) for the No. 2 Fuel delivery pipe.
      G07671829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REINSTALL THE FUEL PRESSURE SENSOR CONNECTOR. 
    G07671830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY 
    1. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.
    2. Install a NEW  O-ring, NEW  backup rings (No. 1 and No. 2) and NEW  E-ring to the fuel pipe.
      NOTE:
      • Check that there is no foreign matter or damaged areas in the pipe's O-ring groove.
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
      • Check that the fuel pipe installation end is not contaminated with foreign matter and is not damaged.
        G07671831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply gasoline to the No. 3 fuel pipe's O-ring and into the attachment hole of the delivery pipe's No. 3 fuel pipe.
      NOTE:
      • Do not over apply lubricant.
      • Apply gasoline on both the O-ring and into the attachment hole. Lubricant will run out immediately after insertion if only applied to the O-ring side.
        G07671832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hand tighten the 2 stud bolts to the delivery pipe bolt attachment holes. (torx® side up)
      G07671833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Press the fuel pipe and delivery pipe together by hand until there is no gap between them.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 stud bolts.
      G07671835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Loosely install the No. 3 fuel pipe sub-assembly to the fuel pump assembly.
      NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
      G07671836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the 2 bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a 19 mm union nut wrench, connect the fuel pipe.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

      G07671838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY 
    1. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.
    2. Install a NEW  O-ring, NEW  backup rings (No. 1 and No. 2) and NEW  E-ring to the fuel pipe.
      NOTE:
      • Check that the No. 1 and No. 2 backup rings are installed in the correct direction.
      • Make sure that 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 as shown in the illustration.
      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
      • Check that the fuel pipe installation end is not contaminated with foreign matter and is not damaged.
        G07671839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply gasoline to the No. 2 fuel pipe's O-ring and into the attachment hole of the delivery pipe's No. 2 fuel pipe.
      NOTE:
      • Do not over apply lubricant.
      • Apply gasoline on both the O-ring and into the attachment hole. The gasoline will run out immediately after insertion if only applied to the O-ring side.
        G07671840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hand tighten the 2 stud bolts to the delivery pipe bolt attachment holes. (torx® side up)
      G07671841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Press the fuel pipe and delivery pipe together by hand until there is no gap between them.
    6. Remove the 2 stud bolts.
      NOTE: Shifting the pipe too widely to the left and right may damage the part which may lead to a fuel leak.
      G07671842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Loosely install the No. 2 fuel pipe sub-assembly to the fuel pump assembly.
      NOTE: Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
      G07671843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the 2 bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a 19 mm union nut wrench, connect the fuel pipe.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

      G07671845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Once the 2 NEW  gaskets and fuel tube have been installed, attach the fuel pressure pulsation damper RH and tighten by hand.
      NOTE:
      • Do not damage the seal surface when installing the pipe and fuel pump. Doing so may lead to a fuel leak.
      • Do not use pulsation dampers which have been dropped. Dropped dampers may not work properly.
      • Do not blow air into the pulsation dampers. The air pressure may damage the internal diaphragm.
        G07671846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Once the 2 NEW  gaskets and fuel tube have been installed, attach the fuel pressure pulsation damper LH and tighten by hand.
      G07671847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt illustrated.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the bolt illustrated.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Use SST or equivalent, securely tighten the fuel pressure pulsation damper RH.

      SST 09612-24014 (09617-24011) 

      Torque Specification: 

      With SST 

      33 N.m (337 kgf.cm, 24 ft.lbf) 

      With out SST 

      40 N.m (408 kgf.cm, 30 ft.lbf) 

      G07671850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Use SST or equivalent, securely tighten the fuel pressure pulsation damper LH.

      SST 09612-24014 (09617-24011) 

      Torque Specification: 

      With SST 

      33 N.m (337 kgf.cm, 24 ft.lbf) 

      With out SST 

      40 N.m (408 kgf.cm, 30 ft.lbf) 

      G07671851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the 3 fuel hoses. (illustration below)
      G07671852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the bracket with the bolt.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT NO. 3 FUEL HOSE 
    1. Remove the plastic bag and protective tape and clean the attachment surface.
      NOTE: Check for damage or foreign objects on the connector.
      G07671854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push in the fuel tube connector to the delivery pipe sub-assembly and push up the retainer to engage the claws.
    3. Install the fuel pipe clamp.
      NOTE: After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      G07671855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT PCV HOSE 
    1. Connect the PCV hose.
      G07671856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY 
    1. Hand tighten the fuel pipe.
    2. Using a 19 mm union nut wrench, tighten the fuel pipe in the order shown in the illustration.

      Torque Specification: 26 N.m (265 kgf.cm, 19 ft.lbf) 

      G07671857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL ENGINE COVER SUB-ASSEMBLY 
    1. Install the 3 engine covers.
      G07671858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 3 ENGINE COVER SUB-ASSEMBLY 
    1. Install the No. 3 engine cover sub-assembly with the 2 clips.
      G07671859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bracket with the 2 bolts.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the clamp.
      G07671861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
E. REINSTALL THE INTAKE MANIFOLD
  1. REINSTALL INTAKE MANIFOLD 
    1. Remove the protective tape and clean the attachment surface.
    2. Install 2 NEW  gaskets.
    3. Have one person assist by lifting the engine wire harness.
    4. Install the intake manifold from the right bank.
      G07671862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a 12 mm deep socket wrench, install the 8 bolts and 2 nuts.

      Torque Specification: 21 N.m (214 kgf.cm, 15 ft.lbf) 

      G07671863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the bolt located on the rear of the manifold.

      Torque Specification: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07671864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REINSTALL THE REMAINING COMPONENTS IN THE REVERSE ORDER OF REMOVAL. 
    NOTE: Use the illustrations on this page and the next page for assistance and torque specifications during reinstallation.
    G07671865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    G07671866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Reinstall and reconnect the battery and insulator.
    2. Install the cowl top ventilator lover RH.
      G07671867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
E. CHECK FOR FUEL LEAKS & REASSEMBLY
  1. CHECK FOR FUEL LEAKS 
    1. Connect the Techstream to the DLC3.
    2. Push the engine switch on (IG).
      NOTE: Do not start the engine.
    3. Push the tester ON.
    4. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump Speed.
    5. Check that there are no fuel leaks anywhere on the system after performing maintenance. If there is a fuel leak, repair or replace parts as necessary.
  2. COOLANT REPLACEMENT 
    1. Click the link for additional assistance.

      1UR-FSE COOLING: COOLANT: REPLACEMENT (2007 LS460) 

  3. REINSTALL ENGINE ROOM COVERS 
    G07671868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CHECK THROTTLE BODY 
    1. Check the throttle control motor operating sounds.
      1. Push the engine switch on (IG).
      2. When pressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor. If friction noise exists, replace the throttle body.
    2. Check the throttle position sensor.
      1. Connect the techsream to the DLC3.
      2. Push the engine switch on (IG).
      3. Push the tester main switch ON.
      4. Enter the following menus: Powertrain / Engine / Data List / Throttle Sensor Position.
      5. Depress the accelerator pedal. When the throttle value is fully opened, check that the value of the "Throttle Sensor Position" is within the specification.

      Standard throttle valve opening percentage: 60? or more. 

      NOTE: When checking the standard throttle valve opening percentage, the shifter should be in the N position.
      NOTE: If the percentage is less than 60?, replace the throttle body.
  5. TEST DRIVE AND CHECK FOR DTC'S 
    1. Test drive the vehicle, inspect for any abnormalities. (warning lamps, driveability, etc.)
    2. If an error code displays, repair as necessary.
  6. PERFORM INITIALIZATIONS 
    NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
    1. Navigation system (for DVD) initialization.
    2. Correction of steering angle neutral point.
    3. Rear curtain position reset operation.
    4. Reset power trunk lid system.

VIII. APPENDIX

A. CAMPAIGN PARTS DISPOSAL

As required by Federal Regulations, please make sure all campaign parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused.

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