Lexus ES manuals

Lexus ES: Removal

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / 2gr-fks (fuel) / Fuel Injector (for Direct Injection) / Removal

REMOVAL

CAUTION / NOTICE / HINT

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

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

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Battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Control System (for Gasoline Model)

Pre-collision System (for Gasoline Model)

Parking Support Brake System (for Gasoline Model)*

Lighting System (for Gasoline Model)

Memorize steering angle neutral point

Parking Assist Monitor System (for Gasoline Model)

Panoramic View Monitor System (for Gasoline Model)

Initialize power trunk lid system

Power Trunk Lid System (for Gasoline Model)

  • Replacement of direct fuel injector assembly
  • Replacement of fuel pressure sensor (fuel delivery pipe with sensor assembly LH)
  • Replacement of port fuel injector assembly
  • Replacement of fuel pressure sensor (fuel delivery pipe with sensor assembly)
  • Replacement of fuel pump assembly
  • Replacement of throttle body with motor assembly
  • Cleaning the deposits from the throttle body with motor assembly

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

CAUTION:

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

NOTICE:

  • After the engine switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Audio and Visual System)
  • After the engine switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Navigation System)

PROCEDURE

1. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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2. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

CAUTION:

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

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

(b) Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.

3. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.

(b) Disengage the 2 clamps to remove the wire harness clamp bracket.

4. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

(a) Disconnect the fuel pressure sensor connector.

(b) Remove the bolt.

(c) Disengage the clamp to disconnect the No. 7 engine wire from the fuel delivery pipe with sensor assembly LH.

(d) Remove the 2 bolts, 2 nuts and fuel delivery pipe with sensor assembly LH with the 3 direct fuel injector assemblies from the cylinder head LH.

Bolt

Nut

NOTICE:

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

(e) Disconnect the 3 direct fuel injector assembly connectors.

5. REMOVE FUEL DELIVERY PIPE RH

(a) Remove the bolt.

(b) Disengage the clamp to disconnect the No. 6 engine wire from the fuel delivery pipe RH.

(c) Remove the 2 bolts, 2 nuts and fuel delivery pipe RH with the 3 direct fuel injector assemblies from the cylinder head sub-assembly.

Bolt

Nut

NOTICE:

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

(d) Disconnect the 3 direct fuel injector assembly connectors.

6. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

(a) Secure the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH in a vise between aluminum plates and pull out the 6 direct fuel injector assemblies.

NOTICE:

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

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

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

NOTICE:

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

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

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

7. REMOVE FUEL INJECTOR SEAL

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

NOTICE:

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

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

READ NEXT:

 Inspection

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

 Installation

INSTALLATION PROCEDURE 1. INSTALL FUEL INJECTOR SEAL (a) Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the direct fuel injector

 Fuel Injector (for Port Injection)

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