Sfi System: Removal & Installation Lexus LX J100 рестайлинг

REMOVAL

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1. REMOVE NO.1 REAR SEATS
2. REMOVE REAR DOOR SCUFF PLATES, STEP PLATES AND REAR SEAT LOCK COVERS
3. REMOVE FLOOR SERVICE HOLE COVER Take off the front and rear floor carpels. Remove the 2 Screws and service hole cover.
4. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
5. DISCONNECT FUEL MAIN TUBE AND RETURN TUBE (FUEL TUBE CONNECTORS) FROM FUEL SUCTION PLATE CAUTION: Perform disconnecting operation of the fuel tube connector (quick type) after reading the precautions. (See «PRECAUTION»(ref-209797-S18971641052005121100000) ) Prevent the retained pressure in the fuel line from splashing inside the vehicle compartment. Be careful not to damage the contact surface or let the foreign matters on there when sealing the tube and the suction plates with the quick connectors through O-ring. Be sure to perform the disconnection by hand. Do not use tools. Do not bend or turn the nylon tube by force. Before the operation, remove foreign matters or dirt sticking to the tube joint clips. Enlarge the tip of the clips with fingers and pull them out for disconnection. Pull out the fuel main tube and the return tube. If the nylon tube and the suction plate stick together, ease the connection by turning the nylon tube with fingers and pull it out for disconnection. NOTE: Plug the port of the fuel suction plate with a clean rubber cap. After the disconnection, protect the connector with a plastic bag.
6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK Remove the 8 bolts. Pull out the fuel pump and the sender gauge assembly. NOTE: Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should not bent. Remove the gasket from the fuel section plate.
7. REMOVE LEAD WIRE FROM FUEL PUMP
8. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET Pull out the lower side of the fuel pump from the pump bracket. Disconnect the fuel hose from the fuel pump, and remove the fuel pump. Remove the rubber cushion from the fuel pump.
9. REMOVE FUEL PUMP FILTER FROM FUEL PUMP Using a small screwdriver, remove the clip. Pull out the pump filter.

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1. REMOVE V-BANK COVER
2. REMOVE FUEL PRESSURE REGULATOR Disconnect these hoses from the pressure regulator: Vacuum sensing hose from intake air resonator Fuel return hose CAUTION: Put a shop rag under the pressure regulator. Remove the 2 bolts, and pull out the pressure regulator. Remove the O-ring from the pressure regulator.

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1. INSTALL FUEL PRESSURE REGULATOR Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. While turning the pressure regulator left and right, install it to the delivery pipe. Install the pressure regulator with the 2 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) Connect these hoses to the pressure regulator: Vacuum sensing hose to the intake air resonator Fuel return hose
2. CHECK FOR FUEL LEAKS (See «PRECAUTION»(ref-209797-S18971641052005121100000) )
3. INSTALL V-BANK COVER

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1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR
3. INSPECT INJECTOR RESISTANCE Disconnect the 8 injector connectors. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 - 14.2 +/- 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
5. REINSTALL V-BANK COVER

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1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR
3. REMOVE FUEL PRESSURE PULSATION DAMPER Remove the pulsation damper, the upper gasket, the fuel main hose and the lower gasket. CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the pulsation damper.
4. DISCONNECT ENGINE WIRE PROTECTOR FROM UPPER INTAKE MANIFOLD Remove and disconnect these parts: PCV hose from the PCV valve VSV for EVAP from the upper intake manifold No.1 V-bank cover bracket from the upper intake manifold No.2 V-bank cover bracket from the upper intake manifold No.3 V-bank cover bracket from the upper intake manifold No.4 V-bank cover bracket from the upper intake manifold Remove the 2 bolts, and disconnect the engine wire protector from the upper intake manifold. Disconnect the engine wire clamp from the No.1 engine hanger.
5. DISCONNECT ENGINE WIRE FROM RH DELIVERY PIPE Disconnect the 2 wire clamps on the engine wire from the brackets on the delivery pipe
6. REMOVE DELIVERY PIPES AND INJECTORS NOTE: Be careful not to drop the injectors when removing the delivery pipes. Since the O-ring may be stuck to the injector, do not put a side load on it at the removal. Remove the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Remove the bolt, the 2 union bolts, the 4 gaskets and front fuel pipe. Disconnect the 8 injector connectors. Remove the 4 nuts holding the delivery pipes to the lower intake manifold. Remove the 2 delivery pipes, the 8 injectors, 4 spacers and the 8 insulators. Remove the O-ring and the grommet 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 (fuel tube connector) from the fuel filter. CAUTION: Perform disconnecting operations of the fuel tube connector (quick type) after reading the precautions (See «PRECAUTION»(ref-209797-S18971641052005121100000) ). Prevent the retained pressure in the fuel pipe line from splashing inside the engine compartment. Purchase the new fuel main hose and take out the fuel tube connector from its hose. Part No. 23271-50150 Connect SST (hose) and fuel tube connector to the fuel filter outlet. SST 09268-41047 CAUTION: Perform connecting operations of the fuel tube connector (quick type) after reading the precautions (See «PRECAUTION»(ref-209797-S18971641052005121100000) ). HINT: Use the vehicle's fuel filter. Remove the pressure regulator from the delivery pipe. Install the O-ring to the fuel inlet of the pressure regulator. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268-41047 (09268-41091) Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) Connect the fuel return hose to the fuel outlet of the pressure regulator. Install the O-ring to the injector. Connect SST (adaptor 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 the LEXUS hand-held OBD II scan tool tester to the DLC3. Connect the battery negative (-) cable to the battery. Turn the ignition switch ON, and press the LEXUS hand-held tester or OBD II scan tool main switch ON. NOTE: Do not start the engine. Select the ACTIVE TEST mode on the LEXUS hand-held tester or OBD II scan tool. Please refer to the LEXUS hand-held tester or OBD II scan tool operator's manual for further details. If you have no LEXUS hand-held tester or OBD II scan tool, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See «FUEL PUMP»(ref-209797-S20312392262005121100000) ). Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 56 - 69 cm 3 (3.4 - 4.2 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 SST and fuel tube connector. SST 09268-41047, 09842-30070 Disconnect the LEXUS hand-held tester or OBD II scan tool from the DLC3. Reconnect the fuel inlet pipe (fuel tube connector) to the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after reading the precautions (See «PRECAUTION»(ref-209797-S18971641052005121100000) ).

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1. INSTALL INJECTORS AND DELIVERY PIPES NOTE: Be careful not to drop the injectors when installing the delivery pipes. Since the O-ring may be stuck to the injector, do not put a side load on it at the removal. Install a new grommet to each injector. Apply a light coat of gasoline to 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 and 8 new insulators on the intake manifold. Place the 2 delivery pipes and the injectors assemblies on the lower intake manifold. Temporarily install the 4 nuts. Install the front fuel pipe with the bolt, the 4 new gaskets and the 2 union bolts. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) for union bolts 7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt Install the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 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 in that case. Position the injector connector outward. Tighten the 4 nuts holding the delivery pipes to the lower Intake manifold. Fig. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) Connect the 8 injectors connectors.
2. INSTALL ENGINE WIRE TO LH DELIVERY PIPE Install the 2 wire clamps on the engine wire to the brackets on the delivery pipe.
3. INSTALL ENGINE WIRE PROTECTOR Connect the engine wire clamp to the No.1 engine hanger. Install the engine wire protector with the 2 bolts. Connect the PCV hose to the PCV valve. Connect VSV EVAP to the upper intake manifold. Install the No.1 V-bank cover bracket to the upper intake manifold. Install the No.2 V-bank cover bracket to the upper intake manifold. Install the No.3 V-bank cover bracket to the upper intake manifold. Install the No.4 V-bank cover bracket to the upper intake manifold.
4. INSTALL FUEL PRESSURE PULSATION DAMPER (See «PRECAUTION»(ref-209797-S18971641052005121100000) )
5. INSTALL INTAKE AIR CONNECTOR
6. INSTALL V-BANK COVER