Sfi (3UZ-FE): Removal & Installation Lexus GS III

REMOVAL

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1. REMOVE REAR SEAT CUSHION
2. REMOVE FLOOR SERVICE HOLE COVER Remove the 3 cap nuts and service hole cover.
3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
4. DISCONNECT FUEL TANK MAIN TUBE (FUEL TUBE CONNECTOR) FROM FUEL SECTION PLATE CAUTION: Perform disconnecting operation of the fuel tube connector (quick type) after observing precaution. (See «SFI SYSTEM»(ref-229199-S27766862782006042000000) ). As there is retained pressure in the fuel line, prevent it from splashing inside the vehicle compartment. Remove the tube joint clip. Pull out the fuel main tube. Plug the port of the fuel suction plate with a clean rubber cap.
5. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK Remove the 8 bolts and fuel tank vent tube set plate. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge assembly and gasket.
6. REMOVE NO.2 FUEL SUCTION SUPPORT (See «REMOVAL»(ref-229199-S31547065572006042000000) )
7. REMOVE FUEL PRESSURE REGULATOR AND FUEL RETURN JET TUBE ASSEMBLY (See «REMOVAL»(ref-229199-S31547065572006042000000) )
8. REMOVE FUEL FILTER ASSEMBLY AND FUEL PUMP ASSEMBLY WITH FILTER Using 2 screwdrivers, disconnect the 4 snap claws from the claw holes and remove the fuel filter assembly. NOTE: Be careful not to damage the filter assembly and suction plate. Disconnect the fuel pump connector. Remove the O-ring from the fuel port of the fuel suction plate. Pull out the fuel pump assembly with filter.
9. REMOVE FUEL SENDER GAUGE ASSEMBLY Disconnect the connector and slide the fuel sender gauge assembly out of the fuel suction plate.

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1. INSTALL FUEL SENDER GAGE ASSEMBLY Slide the fuel sender gage assembly into the fuel suction plate, and connect the connector.
2. INSTALL FUEL FILTER ASSEMBLY AND FUEL PUMP ASSEMBLY WITH FILTER Push in the fuel pump assembly with filter. Apply a light coat of gasoline to a new O-ring, and install it to the fuel port of the fuel suction plate. connect the fuel pump connector. Push the fuel filter assembly, and attach the 4 snap claws to the claw holes.
3. INSTALL FUEL PRESSURE REGULATOR AND FUEL RETURN JET TUBE ASSEMBLY (See «INSTALLATION»(ref-229199-S05056667712006042000000) )
4. INSTALL NO.2 FUEL SUCTION SUPPORT (See «INSTALLATION»(ref-229199-S05056667712006042000000) )
5. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK Install a new gasket to the fuel suction plate. Connect the fuel sub-suction hose to the fuel return jet tube. Attach the fuel pump and sender gauge assembly to the fuel tank. Install the fuel tank vent tube set plate with the 8 bolts. Torque: 3.5 N.m (36 kgf.cm, 31 in..lbf)
6. CONNECT FUEL TANK MAIN TUBE (FUEL TUBE CONNECTOR) TO FUEL SUCTION PLATE Attach the fuel tube connector to the port of the fuel suction plate. Install the tube joint clip.
7. CONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
8. CHECK FOR FUEL LEAKS (See «SFI SYSTEM»(ref-229199-S27766862782006042000000) )
9. INSTALL FLOOR SERVICE HOLE COVER Install the service hole cover with the 3 cap nuts.
10. INSTALL REAR SEAT CUSHION

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1. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK (See «REMOVAL»(ref-229199-S22356400932006042000000) )
2. REMOVE NO.2 FUEL SUCTION SUPPORT Using 2 screwdrivers, disconnect the 3 snap claws from the claw holes and remove the fuel suction support. NOTE: Be careful not to damage the suction support and fuel filter. Remove the rubber cushion.
3. REMOVE FUEL PRESSURE REGULATOR AND FUEL RETURN JET TUBE ASSEMBLY Disconnect the fuel return jet tube from the clamp of the fuel filter. Pull out the fuel pressure regulator from the fuel filter, and remove the fuel pressure regulator and fuel return jet tube assembly. Remove the O-ring from the fuel pressure regulator.

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1. INSTALL FUEL PRESSURE REGULATOR AND FUEL RETURN JET TUBE ASSEMBLY Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator. Push in the fuel pressure regulator to the fuel filter. Check that the fuel pressure regulator rotates smoothly. If it does not rotates smoothly, the O-ring may be pinched, so remove the fuel pressure regulator and perform again steps b and (c) above. Connect the fuel return jet tube to the clamp of the fuel filter.
2. INSTALL NO.2 FUEL SUCTION SUPPORT Install the rubber cushion to the fuel pump. Push the fuel suction support, and attach the 3 snap claws to the claw holes.
3. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK (See «INSTALLATION»(ref-229199-S25605273112006042000000) )

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1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR PIPE
3. INSPECT INJECTOR RESISTANCE Disconnect the 8 injector connectors. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 - 14.2 ohm at 20°C (68°F) If the resistance is not as specified, replace the injector. Reconnect the 8 injector connectors.
4. REINSTALL INTAKE AIR CONNECTOR PIPE
5. REINSTALL V-BANK COVER

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1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR PIPE
3. DISCONNECT ENGINE WIRE PROTECTOR FROM UPPER INTAKE MANIFOLD AND BEARING CAP Remove and disconnect these parts: VSV connector for EVAP PCV hose from upper intake manifold EVAP hose from VSV for EVAP No. 3 V-bank cover bracket from No.1 engine hanger VSV for EVAP from upper intake manifold No. 2 V-bank cover bracket from upper intake manifold Remove the 4 bolts, and disconnect the engine wire protector from the upper intake manifold and camshaft bearing cap.
4. DISCONNECT ENGINE WIRE FROM RH DELIVERY PIPE Disconnect the 2 wire clamps on the engine wire from the brackets on the delivery pipe
5. REMOVE FUEL PRESSURE PULSATION DAMPERS (See «REMOVAL»(ref-229199-S30823170272006042000000) )
6. REMOVE DELIVERY PIPES AND INJECTORS NOTE: Be careful not to drop the injectors when removing the delivery pipes. Pay attention to put any hung load on the injector to and from the side direction. Remove the bolt, and disconnect the No. 1 V-bank cover bracket from the upper intake manifold. Remove the 2 nuts and V-bank cover bracket sub-assembly. Disconnect the 8 injector connectors. Remove the 4 nuts holding the delivery pipes to the lower intake manifold. Remove the 2 delivery pipes, 8 injectors and 4 spacers. No.5, No.6, No.7 and No.8 Injectors: Remove the injector cover from each injector. Remove the 2 O-rings, grommet and insulator from each injector.

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1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. Disconnect the fuel inlet hose (rear fuel pipe) from the fuel main tube. Temporarily install SST (union) to the fuel main tube. SST 09268-41047 (09268-52011) Tighten the flare nut on the fuel main tube. (See «SFI SYSTEM»(ref-229199-S27766862782006042000000) ) Connect SST (hose) to the SST (union). SST 09268-41047 Install the O-ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41047 (09268-41110, 09268-41300) Put the injector into the graduated cylinder. CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. Connect a LEXUS hand-held tester to the DLC3. Connect the battery negative (-) cable to the battery. Turn the ignition switch ON, and push the LEXUS handheld tester main switch ON. NOTE: Do not start the engine. Select the active test mode on the LEXUS hand-held tester. Refer to the LEXUS hand-held tester or OBDII scan tool operator's manual for further details. If you have no LEXUS hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (See «FUEL PUMP»(ref-229199-S00004665932006042000000) ) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 60 - 73 cm 3 (3.7 - 4.5 cu in.) per 15 seconds Difference between each injector: 13 cm 3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE In the condition above, disconnect the tester probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 12 minutes Turn the ignition switch OFF. Disconnect the negative (-) terminal cable from the battery. Remove the SST. SST 09268-41047, 09842-30070 Disconnect the LEXUS hand-held tester from the DLC3. Reconnect the fuel inlet hose (rear fuel pipe) to the fuel main tube. (See «SFI SYSTEM»(ref-229199-S27766862782006042000000) )

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1. INSTALL INJECTORS AND DELIVERY PIPES NOTE: Be careful not to drop the injectors when installing the delivery pipes. Pay attention to put any hung load on the injector to and from the side direction. Install a new grommet and new insulator to each injector. Apply a light coat of gasoline to 2 new O-rings and install them to each injector. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 8 injectors. Position injector connector outward. Place the 4 spacers on the intake manifold. Place the 2 delivery pipes and injectors assemblies on the lower intake manifold. Temporarily install the 4 nuts. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings. Position injector connector outward. Tighten the 4 nuts holding the delivery pipes to the lower intake manifold. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Connect the 8 injectors connectors. Install the V-bank cover bracket sub-assembly with the 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Install the No. 1 V-bank cover bracket with the bolt.
2. INSTALL FUEL PRESSURE PULSATION DAMPERS (See «INSTALLATION»(ref-229199-S14618740362006042000000) )
3. INSTALL ENGINE WIRE TO LH DELIVERY PIPE Install the 2 wire clamps on the engine wire to the brackets on the delivery pipe.
4. INSTALL ENGINE WIRE PROTECTOR Install the engine wire protector with the 4 bolts. Install and connect these parts: VSV connector for EVAP PCV hose to upper intake manifold EVAP hose to VSV for EVAP No. 3 V-bank cover bracket to No.1 engine hanger VSV for EVAP to upper intake manifold No. 2 V-bank cover bracket to upper intake manifold
5. INSTALL INTAKE AIR CONNECTOR PIPE
6. INSTALL V-BANK COVER

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1. REMOVE V-BANK COVER
2. DISCONNECT ENGINE WIRE PROTECTOR FROM UPPER INTAKE MANIFOLD AND BEARING CAP Remove and disconnect these parts: PCV hose from upper intake manifold EVAP hose from VSV for EVAP No. 3 V-bank cover bracket from No.1 engine hanger VSV for EVAP from upper intake manifold No. 2 V-bank cover bracket from upper intake manifold Remove the 4 bolts, and disconnect the engine wire protector from the upper intake manifold and camshaft bearing cap.
3. REMOVE FUEL PRESSURE PULSATION DAMPERS Remove the pulsation damper, upper gasket and lower gasket. CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the pulsation damper.

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1. INSTALL FUEL PRESSURE PULSATION DAMPERS Temporarily install the lower gasket, rear fuel pipe, upper gasket and pulsation damper. Temporarily install the 2 pulsation dampers. Remove the 2 bolts and air tube. Disconnect the engine wire clamp from the bracket. Disconnect the No.5 ignition coil connector. Disconnect the No.7 injector connector. Using SST, tighten the pulsation dampers. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Reconnect the No.7 injector connector. Reconnect the No.5 ignition coil connector. Reinstall the engine wire clamp to the bracket. Reinstall the air tube with the 2 bolts.
2. INSTALL ENGINE WIRE PROTECTOR Install the engine wire protector with the 4 bolts. Install and connect these parts: PCV hose to upper intake manifold EVAP hose to VSV for EVAP No. 3 V-bank cover bracket to No.1 engine hanger VSV for EVAP to upper intake manifold No. 2 V-bank cover bracket to upper intake manifold
3. CHECK FOR FUEL LEAKS (See «SFI SYSTEM»(ref-229199-S27766862782006042000000) )
4. INSTALL V-BANK COVER

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1. Check the fuel lines for cracks or leakage, and all connections for deformation.
2. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage.
3. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness.
4. Check the filler neck for damage or fuel leakage.
5. Hose and pipe connections are as shown in the illustration.

If a problem is found, repair or replace the parts as necessary.

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1. REMOVE AIR FLOW METER Disconnect the air flow meter connector. Remove the 2 screws, air flow meter and O-ring.
2. INSPECT AIR FLOW METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. AIR FLOW METER RESISTANCE Terminals Resistance Temperature THA - E2 13.6 - 18.4 kohm -20 °C (-4°F) THA - E2 2.21 - 2.69 kohm 20°C (68°F) THA - E2 0.49 - 0.67 kohm 60°C (140°F) If the resistance is not as specified, replace the air flow meter.
3. INSPECT AIR FLOW METER OPERATION Connect the air flow meter connector. Turn the ignition switch to ON. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. Blow air into the air flow meter, and check that the voltage fluctuates. If operation is not as specified, replace the air flow meter. Turn the ignition switch LOCK. Disconnect the air flow meter connector.
4. INSTALL AIR FLOW METER Install a new O-ring and the air flow meter with the 2 screws. Connect the air flow meter connector.

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1. REMOVE V-BANK COVER
2. INSPECT SYSTEM OPERATION Inspect the throttle control motor for operating sound. Turn the ignition switch ON. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3 ), wiring and ECM. Inspect the accelerator pedal position sensor. Connect the LEXUS hand-held tester or OBDII scan tool to the DLC3. Turn the ignition switch ON. Check that the check engine warning light does not light up. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5 ), wiring and ECM. If you have no LEXUS hand-held tester, measure voltage between terminals VTA and ETA of the ECM connector. (See «TERMINALS OF ECM»(ref-229176-S31952948692006042000000) ). Inspect the idle speed. Start the engine and check that the MIL does not light up. Allow the engine to warm up to normal operating temperature. Turn the A/C conditioning ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 750 +/- 50 RPM NOTE: Perform inspection under condition without electrical load. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity.
3. INSPECT THROTTLE CONTROL MOTOR Disconnect the throttle control motor connector. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 -100 ohm at 20°C (68°F) If the resistance is not as specified, replace the throttle body (See «COMPONENTS»(ref-229199-S12021516842006042000000) ). Reconnect the throttle control motor connector.
4. INSPECT THROTTLE POSITION SENSOR Disconnect the throttle position sensor connector. Using an ohmmeter, measure the resistance between terminals VC and ETA. Resistance: 1.25 - 2.35 kohm at 20°C (68°F) If the resistance is not as specified, replace the throttle position sensor (See «REPLACEMENT»(ref-229199-S24681718212006042000000) ). Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR Disconnect the accelerator pedal position sensor connector. Using an ohmmeter, measure the resistance between each terminals. Resistance: ACCELERATOR PEDAL POSITION SENSOR TERMINAL RESISTANCE Terminals Resistance V CP1 - E P1 V CP2 - E P2 1.5 - 6.0 kohm If the resistance is not as specified, replace the accelerator pedal assembly with accelerator pedal position sensor. Reconnect the accelerator pedal position sensor connector.
6. REINSTALL V-BANK COVER

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1. REMOVE V-BANK COVER
2. DRAIN ENGINE COOLANT
3. REMOVE INTAKE AIR CONNECTOR PIPE
4. REMOVE THROTTLE BODY Disconnect the connectors and wire. Disconnect the water bypass hose from the No.5 water bypass pipe on the throttle body. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. Disconnect the water bypass hose from the manifold thermostat on the throttle body, and remove the throttle body. Remove the gasket.

REPLACEMENT

Note. To prevent deterioration, do not shock the throttle position sensor. Mixing of the foreign objects may cause the gear locking, so thoroughly check that there is no stuck of any foreign objects and clean up if any.

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1. Remove the 2 set screws and throttle position sensor.
2. Reinstall a new throttle position sensor. Check that the throttle valve is under the condition of the opener opening angle (about 4°). Install the sensor to the place where is at 15° rotated to the right from the specified installation position. Gradually turn sensor counterclockwise until it touches the throttle valve shaft, and temporarily tighten the 2 set screws.
3. Adjust the throttle position sensor. Connect the throttle position sensor connector. Connect the LEXUS hand-held tester or OBDII scan tool to the DLC3. Turn the ignition switch ON. NOTE: After turning the ignition switch ON, do not depress the accelerator pedal. While reading the valve of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA, turn the throttle position sensor slowly to left and right and set the sensor at the center value of the standard value, and then tighten the screws. Standard throttle valve opening percentage: 14.4 - 16 % Torque: 2.0 N.m (20 kgf-cm, 18 in..lbf) NOTE: After turning the ignition switch ON, do not depress the accelerator pedal. Recheck throttle valve opening percentage. If the throttle valve opening percentage is not as specified, repeat step 4 . Perform fully closed throttle valve by hand and check that the valve of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA stays with the standard value. Standard throttle valve opening percentage: 10 - 14 % If the throttle valve opening percentage is not as specified, repeat steps 4 to 6 . Paint the 2 set screws. Turn the ignition switch OFF. Disconnect the LEXUS hand-held tester or OBDII scan tool from the DLC3. Disconnect the throttle position sensor connector.

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1. INSTALL THROTTLE BODY Connect the water bypass hose to the manifold thermostat on the throttle body. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Connect the water bypass hose to the No. 5 water bypass pipe on the throttle body. Connect the connector.
2. INSTALL INTAKE AIR CONNECTOR PIPE
3. FILL WITH ENGINE COOLANT (See «COOLANT»(ref-229200-S18710022182006042000000) )
4. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS
5. INSTALL V-BANK COVER

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1. REMOVE V-BANK COVER
2. Oil Control Valve (Bank 2): REMOVE INTAKE AIR CONNECTOR PIPE
3. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE RESISTANCE Disconnect the oil control valve connectors. Using an ohmmeter, measure the resistance between the terminals. Resistance: 6.9 - 7.9 ohm at 20°C (68°F) If the resistance is not as specified, replace the valve. Reconnect the oil control valve connectors.
4. Oil Control Valve (Bank 2): REINSTALL INTAKE AIR CONNECTOR PIPE
5. REINSTALL V-BANK COVER

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1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR PIPE
3. REMOVE THROTTLE BODY (See «REMOVAL»(ref-229199-S19474766672006042000000) )
4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (BANK1) Remove the bolt, and disconnect the engine wire protector from the camshaft bearing cap. Disconnect the oil control valve connector. Remove the bolt and oil control valve. Remove the O-ring from the oil control valve.
5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (BANK 2) Disconnect the oil control valve connector. Remove the bolt and oil control valve. Remove the O-ring from the oil control valve.