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Home >> Lexus >> 2024 >> RX 500h >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System - Service Information (1 Of 2) >> FUEL INJECTOR (for Direct Injection) >> Removal [10/2022 - ] >> Procedure

Removal [10/2022 - ]: Procedure

  1. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
  2. DISCONNECT WIRE HARNESS 
    1. GTY1076962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    NOTE:
    • If fuel intrudes into the combustion chamber, there may be adverse affects to the engine main body.
    • When replacing the fuel delivery pipe sub-assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.
    • Make sure not to touch or strike the tips of the direct fuel injector assemblies.
    • Make sure to support the resin part of each direct fuel injector assembly during removal to prevent a direct fuel injector assembly from falling.
    • Pull and remove the fuel delivery pipe sub-assembly in a straight line without tilting it.
    1. GTY1077576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 5 bolts from the fuel delivery pipe sub-assembly.
      2. Install SST to the location shown in the illustration.
        • SST: 09260-48020 
      3. Remove the fuel delivery pipe sub-assembly from the cylinder head sub-assembly vertically.
  4. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 
    NOTE:
    • To prevent bending the nozzle of the direct fuel injector assembly, do not hold it by the nozzle part.
    • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe sub-assembly 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 sub-assembly 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.
      GTY1076472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Cover the tip of each direct fuel injector assembly to prevent it from being damaged.
    1. When removing the direct fuel injector assemblies together with the fuel delivery pipe sub-assembly, perform the following procedure.(Perform step (b) if a direct fuel injector assembly remains attached to the engine side.):
      GTY1077116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Secure the fuel delivery pipe sub-assembly in a vise between aluminum plates.
      2. Pull out the 4 direct fuel injector assemblies.
    2. Perform the following procedure if a direct fuel injector assembly remains attached to the engine side.:
      NOTE:

      Make sure to use SST if a direct fuel injector assembly remains attached to the engine side.

      GTY1077457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bridge Part *b Hold
      *c Turn - -
      1. Install SST (A) to the installation hole of the fuel delivery pipe sub-assembly near the direct fuel injector assembly.
        • SST: 09260-48010 
      2. Install SST (B) to the direct fuel injector assembly and adjust so that the bridge part of SST (B) is at a right angle to SST (A) as shown in the illustration.

        HINT: 

        If the nozzle holder clamp is still attached to the direct fuel injector assembly, remove it before installing SST.

      3. Attach and secure SST (C).
      4. Set a torque wrench to SST and remove the direct fuel injector assembly while checking the value of the torque wrench.
        NOTE:

        If the torque exceeds 1.8 N.m (18 kgf/cm, 16 in.lbf) when removing the direct fuel injector assembly, replace it with a new one.

  5. REMOVE NOZZLE HOLDER CLAMP 
    1. GTY1076968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 3 FUEL INJECTOR BACK-UP RING 
    NOTE:

    Do not damage the area that contacts the O-ring.
    1. GTY1076711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.
  7. REMOVE NO. 1 FUEL INJECTOR BACK-UP RING 
    1. GTY1077085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring *2 No. 1 Fuel Injector Back-up Ring
  8. REMOVE C-RING 
    1. GTY1076947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE INJECTOR VIBRATION INSULATOR 
    1. GTY1076944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL INJECTOR SEAL 
    1. GTY1077062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.
        NOTE:
        • 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.
      2. Remove the fuel injector seal from each direct fuel injector assembly.
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