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Installation [04/2013 - 08/2015]: Procedure

WARNING: This page is about a different car, the 2015 Lexus IS 250 and 2014 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL FUEL INJECTOR SEAL 
    1. Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector assembly and its grooves.
      GTY467210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Area to be Cleaned
      NOTE:
      • Do not clean the tip of the fuel injector assembly.
      • Do not use a wire brush to clean the fuel injector assembly.
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
    2. Apply engine oil to the fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the fuel injector assembly with the chamfer facing the tip of the fuel injector assembly as shown in the illustration.
      GTY470522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Guide)
      *b Chamfer
      • SST: 09260-39015 
        1. 09268-03020
    3. Install a new fuel injector seal to SST (holder).
      GTY467816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect
      • SST: 09260-39015 
        1. 09268-03010
      NOTE:

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.

    4. Install SST (holder) with fuel injector seal to the tip of the fuel injector assembly. Slide the fuel injector seal downward into the fuel injector assembly groove (fuel injector assembly connector side) with your fingers as shown in the illustration.
      GTY468479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Holder)
      *b SST (Guide)
      • SST: 09260-39015 
        1. 09268-03010
        2. 09268-03020

      HINT: 

      Check that the fuel injector seal covers the circumference of the fuel injector assembly groove as shown in the illustration.

    5. Using SST (holder), gently press downward on the fuel injector seal (fuel injector assembly connector side), then slowly slide SST (guide) toward the fuel injector assembly tip to settle the fuel injector seal into the fuel injector assembly groove.
      GTY469834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Holder) *b SST (Guide)
      *c Gently Press *d Correct
      *e Incorrect - -
      • SST: 09260-39015 
        1. 09268-03010
        2. 09268-03020
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      HINT: 

      • When using SST (guide) to settle the fuel injector seal into the groove, SST (guide) only needs to be slid upward to the position (A) in the illustration.
      • After using SST (guide) to settle the fuel injector seal into the groove, return SST (guide) to its position (B) in the illustration.
    6. Install a new fuel injector seal to SST (holder).
      GTY467816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Injector Seal
      *a SST (Holder)
      *b Correct
      *c Incorrect
      • SST: 09260-39015 
        1. 09268-03010
      NOTE:

      Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the seal and correcting this problem is very complicated.

    7. Install a new fuel injector seal to the fuel injector assembly groove (fuel injector assembly tip side) as shown in the illustration.
      GTY458155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Holder)
      *b SST (Guide)
      *c Welded Groove
      • SST: 09260-39015 
        1. 09268-03010
        2. 09268-03020
      NOTE:

      Make sure that the fuel injector seal does not slip into the welded groove of the fuel injector assembly shown in the illustration. If it does, replace it with a new one.

      HINT: 

      Check that the fuel injector seal covers the circumference of the fuel injector assembly groove as shown in the illustration.

    8. Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly connector side) as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the fuel injector assembly groove.
      • SST: 09260-39015 
        1. 09268-03020
      GTY467954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Guide)
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      HINT: 

      • Set SST (guide) so that its bottom surface and fuel injector seal are flush.
      • If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.
    9. Using SST (holder), gently press downward on the fuel injector seal (fuel injector assembly tip side), then slowly slide SST (guide) toward the fuel injector assembly tip to seat the fuel injector seal into the fuel injector assembly groove.
      GTY463070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Holder) *b SST (Guide)
      *c Gently Press *d Correct
      *e Incorrect - -
      • SST: 09260-39015 
        1. 09268-03010
        2. 09268-03020
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

    10. Slowly slide SST (guide) toward the tip of the fuel injector assembly. When the fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal (fuel injector assembly tip side) as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the fuel injector assembly groove.
      • SST: 09260-39015 
        1. 09268-03020
      GTY459828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Guide)
      NOTE:

      Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

      HINT: 

      • Set SST (guide) so that its bottom surface and fuel injector seal are flush.
      • If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the fuel injector assembly little by little.
    11. After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the fuel injector assembly grooves.
      GTY466869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Normal
      *b Protruding
      *c Deformed
      *d Correct
      *e Incorrect
      NOTE:

      If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

  2. INSTALL FUEL INJECTOR ASSEMBLY 

    HINT: 

    Perform "Inspection After Repair" after replacing the fuel injector assembly.

    Refer to INITIALIZATION [04/2013 - 08/2015]

    1. Install a new O-ring, new No. 1 back-up ring, new No. 2 back-up ring, new No. 3 back-up ring, and new E-ring to the fuel injector assembly as shown in the illustration.
      GTY465653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Back-up Ring *2 No. 2 Back-up Ring
      *3 No. 3 Back-up Ring *4 O-ring
      *5 E-ring - -
      *a Alignment Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -
      NOTE:
      • Check that there is no foreign matter or damage on the O-ring groove of the fuel injector assembly.
      • Check that the No. 1 back-up ring and No. 2 back-up ring are installed in the correct direction.
      • Make sure that the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and O-ring are installed in the correct order.
      • Check that the alignment openings of the back-up 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.
    2. Install the injector nozzle holder clamp.
    3. Apply gasoline to the O-ring. Install the injector nozzle holder clamp by aligning the protrusion of the clamp with the notch of the delivery pipe sub-assembly and No. 2 delivery pipe sub-assembly.
      GTY456630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      No Gap
      NOTE:
      • Make sure that there is no gap between the delivery pipe sub-assembly, No. 2 delivery pipe sub-assembly and clamp.
      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the delivery pipe sub-assembly and No. 2 delivery pipe sub-assembly.
      • Insert each fuel injector assembly straight into the delivery pipe sub-assembly and No. 2 delivery pipe sub-assembly without tilting it.
  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Install a new injector vibration insulator to the cylinder head sub-assembly.
    2. Apply lubricant to the fuel injector assembly insertion holes.
    3. Insert the stud bolt into the No. 1 fuel delivery pipe sub-assembly until the screw threads protrude enough so that a nut can be attached.
      GTY462727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut can be attached
      NOTE:
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage on the fuel injector assembly installation holes of the No. 1 fuel delivery pipe sub-assembly.
      • When inserting the No. 1 fuel delivery pipe sub-assembly, push it in evenly without tilting it.
    4. Install the No. 1 fuel delivery pipe sub-assembly by uniformly tightening the 2 bolts and 2 nuts in several steps in the order shown in the illustration.
      Fig 1: No. 1 Fuel Delivery Pipe Sub-Assembly Bolts & Nuts Tightening Sequence
      GTY461626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt
      Front Side

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

    5. Connect the 3 fuel injector assembly connectors and 2 wire harness clamps.
    6. Connect the fuel pressure sensor connector and wire harness clamp.
      GTY456479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Wire Harness
      NOTE:
      • Make sure the wire harness of the fuel pressure sensor passes under the area (A) as shown in the illustration.
      • Do not pull the wire harness of the fuel pressure sensor excessively.
  4. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Install new injector vibration insulators to the cylinder head sub-assembly.
    2. Apply lubricant to the fuel injector assembly insertion holes.
    3. Insert the stud bolt into the No. 2 fuel delivery pipe sub-assembly until the screw threads protrude enough so that a nut can be attached.
      GTY462728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut can be attached
      NOTE:
      • If a fuel injector assembly is dropped or the tip of a fuel injector assembly is struck, replace it with a new one.
      • Check that there is no foreign matter or damage in the fuel injector assembly installation hole of the No. 2 fuel delivery pipe sub-assembly.
      • When inserting the No. 2 fuel delivery pipe sub-assembly, push it in evenly without tilting it.
    4. Install the No. 2 fuel delivery pipe sub-assembly by uniformly tightening the 2 bolts and 2 nuts in several steps in the order shown in the illustration.
      Fig 2: No. 2 Fuel Delivery Pipe Sub-Assembly Bolts & Nuts Tightening Sequence
      GTY460252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt
      Front Side

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

    5. Connect the 3 fuel injector assembly connectors and 3 wire harness clamps.
  5. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY 
    1. Install a new O-ring, new No. 1 back-up ring, new No. 2 back-up ring, new No. 3 back-up ring and new E-ring to each end of the No. 3 fuel pipe sub-assembly as shown in the illustration.
      GTY469744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Back-up Ring *2 No. 2 Back-up Ring
      *3 No. 3 Back-up Ring *4 O-ring
      *5 E-ring - -
      *a Alignment Opening *b Overlapped
      *c Stretched *d Correct
      *e Incorrect - -
      NOTE:
      • Check that there is no foreign matter or damage on the O-ring grooves of the No. 3 fuel pipe sub-assembly.
      • Check that the No. 1 back-up ring and No. 2 back-up ring are installed in the correct direction.
      • Make sure that the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and O-rings are installed in the correct order.
      • Check that the alignment openings of the No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring are not overlapped or stretched as shown in the illustration.
      • After installing the O-rings, check that they are not contaminated with foreign matter and are not damaged.
      • Check that the ends of the No. 3 fuel pipe sub-assembly are not contaminated with foreign matter and are not damaged.
    2. Apply engine oil to the installation hole of the No. 1 fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly.
      GTY460152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No Gap
      Front Side
    3. Press the No. 3 fuel pipe sub-assembly, No. 1 fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly together by hand until there is no gap between them, then install the No. 3 fuel pipe sub-assembly with the 4 bolts.

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

      NOTE:

      Do not install the No. 3 fuel pipe sub-assembly at an angle.

  6. INSTALL FUEL PUMP ASSEMBLY 

    Refer to INSTALLATION [04/2013 - 08/2015] 

  7. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing the fuel injector assembly.

      Refer to INITIALIZATION [04/2013 - 08/2015]

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