Lexus ES300 (1997 year). Service manual — part 522

SF076–06

Z16488

New O–ring

New Insulator

New
O–ring

New Grommet

S04511

Connector

Turn

Push

S04510

Spacer

Spacer

S04500

S04728

Rotate

Outward

SF–22

–

SFI

INJECTOR

873

1997 LEXUS ES300 (RM511U)

INSTALLATION

1.

INSTALL INJECTORS AND DELIVERY PIPES

(a)

Install new insulator and grommet to each injector.

(b)

Apply a light coat of spindle oil or gasoline to 2 new O–
rings and install them to each injector.

(c)

Apply a light coat of spindle oil or gasoline on the place
where a delivery pipe touches an O–ring of the injector.

(d)

While turning the injector clockwise and counterclock-
wise, push it to the delivery pipes. Install the 6 injectors.

(e)

Position the injector connector outward.

(f)

Place the 4 spacers in position on the intake manifold.

(g)

Apply a light coat of spindle oil or gasoline on the place
where a intake manifold touches an O–ring of the injector.

(h)

Place the delivery pipes and fuel pipe together with the 6
injectors in position on the intake manifold.

(i)

Temporarily install the 4 bolts holding the delivery pipes
to the intake manifold.

(j)

Temporarily install the bolt holding the fuel pipe to the in-
take manifold.

(k)

Check that the injectors rotate smoothly.

HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O–rings. Replace the O–rings.
(l)

Position the injector connector outward.

S04499

S06525

Align

S05351

S06086

Fuel Hose
Clamp

S04498

–

SFI

INJECTOR

SF–23

874

1997 LEXUS ES300 (RM511U)

(m)

Tighten the 4 bolts holding the delivery pipes to the intake
manifold.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

(n)

Tighten the bolt holding the fuel pipe to the intake man-
ifold.
Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf)

2.

CONNECT FUEL INLET PIPE

(a)

Align the alignment marks (white paint) on the fuel inlet
pipe.

(b)

Connect the fuel inlet pipe (fuel tube connector) to the fuel
filter.

CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.

(c)

Surely install the fuel hose clamp to the fuel filter with
”click” sound.

(d)

After installing the clamp, check that the clamp is fixed by
pulling up the clamp.

3.

INSTALL AIR ASSIST HOSES AND PIPE

(a)

Connect the air assist hoses to the intake manifold.

(b)

Install the air assist pipe to the bracket on the No.1 fuel
pipe.

4.

CONNECT INJECTOR CONNECTORS

5.

INSTALL AIR INTAKE CHAMBER ASSEMBLY
(See page

EM–52

)

6.

INSTALL AIR CLEANER HOSE

7.

CHECK FOR FUEL LEAKS

SF05U–01

SF–24

–

SFI

FUEL TANK AND LINE

875

1997 LEXUS ES300 (RM511U)

FUEL TANK AND LINE

PRECAUTION

1.

Always use new gaskets when replacing the fuel tank or component parts.

2.

Apply the proper torque to all parts tightened.

SF05V–04

S04763

The Location of Fuel Tank Cushion

No.1 Fuel Tank
Protector

Fuel Tank Vent
Tube Set Plate

Fuel Pump

Fuel Outlet Tube

Fuel Tank

Fuel Inlet Hose

Fuel Inlet Pipe Shield

Fuel Tank Cap

Gasket

Bracket

Fuel Inlet Pipe

Bracket

Fuel Inlet Pipe Protector

Gasket

39 (400, 29)

56 (570, 41)

44 (450, 33)

56 (570, 41)

Heat Insulator

Center Exhaust Pipe

Heated Oxygen Sensor
(Bank 1 Sensor 2)

Fuel Tank Band

Gasket

N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part

Heated Oxygen Sensor (Bank 1 Sensor 2)

HINT:

Before installing the heated oxygen

sensor, twist the sensor wire
counterclockwise 3 and 1/2 turns.

After installing the heated oxygen

sensor, check that the sensor wire is
not twisted, If it is twisted, remove
the heated oxygen sensor and
reinstall it.

Gasket

x8

4 (40, 35 in.·lbf)

–

SFI

FUEL TANK AND LINE

SF–25

876

1997 LEXUS ES300 (RM511U)

COMPONENTS