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Fuel Pipe Replacement (L-CP-7LC)

Publication date: 2007-11-29
Reference number: L-CP-7LC

FUEL PIPE REPLACEMENT

FUEL PIPE REPLACEMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): L-CP-7LC, Date of Issue:  November 29, 2007
LEXUS: 2006 IS 250/350, GS 300
SERVICE CATEGORY: Special Service Campaign
SECTION: General
COPYRIGHT: © 2018 Lexus, a division of Toyota Motor Sales, USA License Agreement TMS1002
NOTE: Additional or supplemental repair information for this procedure has been prepared by Lexus and may be viewed on the lemon2025Tips site by typing http://www.youtube.com/user/lemon2025Tips into your Internet browser.

INTRODUCTION

Dear Dealer Principal: 

Lexus will initiate a Safety Recall (Special Service Campaign) on certain 2006 model year Lexus IS 250/350 and GS 300 vehicles. During the manufacturing process of two specific fuel pipes located in the engine compartment, high stress areas may have been created in the pipes. Combined with other factors such as the presence of corrosive agents in fuel, a crack may form over time leading to fuel leakage. 

The following vital information is provided to inform you and your staff of the owner notification phase of the campaign and your degree of involvement. Additional information may be found in the attached Lexus Q&A and customer notification letter. 

Owner Notification Date

Lexus will begin sending the Safety Recall notification in early December, 2007 via first class mail.

IDENTIFICATION OF INVOLVED VEHICLES

VEHICLE VIN RANGE

MODEL WMI MY VDS Serial Range
GS 300 2WD JTH 2006 BH96S 5000013 - 5026845
GS 300 AWD JTH 2006 CH96S 0001014 - 0013936
IS 250 2WD JTH 2006 BK262 2000010 - 2005190
5000018 - 5007877
IS 250 AWD JTH 2006 CK262 2000003 - 2001160
5000013 - 5003623
IS 350 JTH 2006 BE262 2000000 - 2000995
5000018 - 5002695
NOTE: Dealers should always consult Dealer Daily or TIS to confirm VIN eligibility and to assure that the SSC is applicable. This will verify the vehicle is involved and has not already been completed by another dealer. TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected.

IMPLEMENTATION AT DEALERSHIPS

This SSC package contains the repair instructions, warranty claim procedures, parts order information, a Special Service Tool (quantity of 2 shipped to each dealer) and your dealership's affected VIN list. All associates who have a part in this campaign should be familiar with its contents.

PARTS AVAILABILITY AND ORDERING

The necessary parts can be ordered through your dealership's facing PDC. Lexus will monitor dealer orders for corrective action with any dealer who orders excessive quantities or quantities not commensurate with the vehicle mix sold by the dealer.

PARTS AVAILABILITY AND ORDERING INFORMATION

Vehicle Part Description Part Number Quantity per Vehicle
ALL VEHICLES PIPE SUB-ASSY, FUEL NO. 2 04007-32131 1
ALL VEHICLES PIPE SUB-ASSY, FUEL NO. 3 04007-32231 1
IS 250 / GS 300 GASKET 90430-08014 2
GS 300 GASKET KIT, FUEL PIPE NO. 2 04007-33231 1
IS 250 GASKET KIT, FUEL PIPE NO. 3 04007-33331 1
IS 350 GASKET KIT, FUEL PIPE NO. 4 04007-33431 1

Tools and Equipment

In addition to standard hand tools, a torque wrench, protective tape and the Techstream equipment, the following Special Service Tools (SST) are required.

Warranty Claim Processing Instructions

Dealers are required to submit SSC claims using the information described below.

WARRANTY CLAIM INFORMATION

SSC Opcode Description Labor Hours
7LC 7509L1 Replace the fuel pipes 2.7
NOTE: * Above flat rate time(s) include 0.1 hour for campaign administrative cost per unit for the dealership. Lexus warranty will only accept one claim per vehicle under the terms of the SSC. Please ensure that your dealership checks Dealer Daily or TIS to see if the vehicle has been repaired under this SSC prior  to servicing a vehicle.

Use sublet 'OF' (Other Fluids) to claim $1.00 for a small amount of vehicle oil used in the repair process.

As required by Federal Regulations, please make sure that all original recalled parts removed from a vehicle are disposed of in a manner in which they cannot be reused.

The affected VIN information and operation code will be downloaded and activated for dealerships to use on November 30, 2007.

CUSTOMER CARE

Lexus' usual customer care amenities (car wash, fuel fill-up and loaner vehicles) apply to this SSC. Specific details may be found in TIS in the General Procedures for Limited and Special Service Campaigns.

Please review this entire package with your Service and Parts staff to familiarize them with its contents so they may properly implement this campaign as well as address any owner concerns that may arise regarding this Special Service Campaign. 

Thank you for your understanding. Your on-going care for these Lexus owners during this campaign protects our customers and their image of Lexus.

Sincerely,

Jerry Marcotti

Service and Parts Field Operations Manager

Attachments

CC: Customer Satisfaction Manager

General Manager

Parts Manager

Sales Manager

Service Manager

SPECIAL SERVICE CAMPAIGN (SSC) - 7LC (SAFETY RECALL) Q&A

2006 Model Year Lexus GS 300 (2WD/AWD), IS 250 (2WD/AWD), and IS 350 

Q1: What is the condition? 

A1: There is a possibility that a crack may form over time in two specific fuel pipes in the engine compartment. 

Q2: What is the cause of this condition? 

A2: During the manufacturing process of two specific fuel pipes located in the engine compartment, high stress areas may have been created in the pipes. Combined with other factors such as the presence of corrosive agents in fuel, a crack may form over time leading to fuel leakage. 

Q3: Are there any warnings that this condition exists? 

A3: No, there are no warnings that this condition will occur.

Q4: Which and how many vehicles are involved? 

A4: There are approximately 34,400 vehicles involved.

AFFECTED VEHICLE

Affected Vehicle Approx UIO
2006 model year GS 300 26,300 (14,100 2WD, 12,200 AWD)
2006 model year IS 250 5,430 (3,250 2WD, 2,180 AWD)
2006 model year IS 350 2,650

Q5: Are there any other Toyota or Lexus vehicles involved? 

A5: No, this specific condition only affects certain 2006 model year IS 250/350 and GS 300 vehicles.

Q6: What is the production period of the affected vehicles? 

A6: The affected vehicles were produced: 

VEHICLE PRODUCTION INFORMATION

Model Production Range
2006 model year GS 300 (2WD & AWD) Mid-December 2004 - Late October 2005
2006 model year IS 250 (2WD) Late August 2005 - Mid-December 2005
2006 model year IS 250 (AWD) Mid-August 2005 - Mid-December 2005
2006 model year IS 350 Mid-August 2005 - Early November 2005

Q7: How many incidents of this condition have been reported? 

A7: There has been 1 case of fuel leakage reported in the affected vehicles in the United States from this condition. 

Q8: Have there been any accidents reported? 

A8: No. There have been no accidents reported which relate to this condition.

Q9: What is Lexus going to do? 

A9: Owners of the involved vehicles will receive a Safety Recall Notification by first class mail beginning in early December 2007. Any Lexus dealer will replace the fuel pipes with newly designed ones at NO CHARGE to the vehicle owner. 

Q10: How long will the repair take? 

A10: The repair will take approximately three hours. However, depending upon the dealer's work schedule, it may be necessary to make the vehicle available for a longer period of time.

Q11: What should an owner do if they experience the condition, or have immediate concerns about their vehicle? 

A11: If an owner has any immediate concerns they are requested to contact their local Lexus dealer for diagnosis, and if applicable, repair.

OWNER NOTIFICATION LETTER

Special Service Campaign 7LC 

2006 Model Year IS 250/350 and GS 300 Fuel Pipe Replacement 

Safety Recall Notice 

Dear Lexus Customer:

This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Lexus has decided that a defect, which relates to motor vehicle safety, exists in certain 2006 model year IS 250/350 and GS 300 vehicles.

What is the condition? 

During the manufacturing process of two specific fuel pipes located in the engine compartment, high stress areas may have been created in the pipes. Combined with other factors such as the presence of corrosive agents in fuel, a crack may form over time leading to fuel leakage from the fuel pipe(s). In the worst case, fuel leakage in the presence of an ignition source could result in a fire.

What will Lexus do? 

Any Lexus dealer will replace the two involved fuel pipes with newly designed ones at NO CHARGE to you.

What should you do? 

This is an important Safety Recall 

Please contact your authorized Lexus dealer to make an appointment to replace the two involved fuel pipe with newly designed ones as soon as possible. The repair will take approximately three hours. However, depending upon the dealer's work schedule, it may be necessary to make your vehicle available for a longer period of time.

We request that you present this notice to the dealer at the time of your service appointment. 

If you no longer own the vehicle, please indicate so on the enclosed postage-paid form, providing us with the name and address of the new owner.

What if you have other questions? 

Your local Lexus dealer will be more than happy to answer any of your questions and set up an appointment to perform the repair.  If you require further assistance, you may contact the Lexus Customer Assistance Center at 1-800-255-3987 Monday through Friday, 5:00 am to 6:00 pm, Saturday 7:00 am through 4:00 pm Pacific Standard Time.

If you believe that the dealer or Lexus has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153), or go to http://www.safercar.gov.

If you are a vehicle lessor, Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. 

We have sent this notice in the interest of your continued satisfaction with our products, and we sincerely regret any inconvenience this condition may have caused you.

Thank you for driving a Lexus.

Sincerely,

Lexus Division

TOYOTA MOTOR SALES, U.S.A., INC.

TECHNICAL INSTRUCTIONS

TECHNICAL INSTRUCTIONS 

FOR 

SPECIAL SERVICE CAMPAIGN 7LC 

FUEL PIPE REPLACEMENT 

FOR THE FOLLOWING VEHICLES 

2006 GS 300 

2006 IS 250 

2006 IS 350 

I. OPERATION FLOW CHART

G07658682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

II. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE
AFFECTED VIN RANGE

Model WMI Year VIN Range
VDS Range
GS 300 JTH 2006 BH96S 5000013 - 5026845
CH96S 0001014 - 0013936
AFFECTED VIN RANGE

Model WMI Year VIN Range
VDS Range
IS 250 JTH 2006 BK262 2000010 - 2005190
5000018 - 5007877
CK262 2000003 - 2001160
5000013 - 5003623
AFFECTED VIN RANGE

Model WMI Year VIN Range
VDS Range
IS 350 JTH 2006 BE262 2000000 - 2000995
5000018 - 5002695
NOTE:
  • Not all vehicles in the VIN range may be affected.
  • Check Dealer Daily/TIS to confirm the VIN is involved in this SSC. This will verify the vehicle is affected and has not already been completed prior to dealer shipment or by another dealer.
  • TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were completed by another dealer.

III. BACKGROUND

During the manufacturing process of two specific fuel pipes located in the engine compartment, high stress areas may have been created in the pipes. Combined with other factors such as the presence of corrosive agents in fuel, a crack may form over time leading to fuel leakage from the fuel pipe(s).

IV. PREPARATION

A. TOOLS
  • Standard hand tools
  • Torque wrench
  • SST: Stud Bolt - 04007-32331 (2 stud bolts have been included in each Service Manager's Package.)
  • SST: 09617-24011 (A component of SST 09612-24014, Steering Housing Overhaul Tool Kit) OR  Commercially available 22 mm Crowfoot Wrench
  • Protective tape
B. EQUIPMENT
  • Techstream
C. MATERIALS
  • Tape
D. PARTS
  • GS 300 
    PARTS INFORMATION (GS 300)

    Model Part Number Part Description Quantity
    GS 300 04007-32131 Fuel Pipe Sub-Assembly No. 2 1
    04007-32231 Fuel Pipe Sub-Assembly No. 3 1
    04007-33231 Fuel Pipe Gasket Kit (1) 1
    90430-08014 Gasket 2
    (1) For kit contents refer to section " XIII. APPENDIX  " on page 46. 
  • IS 250 
    PARTS INFORMATION (IS 250)

    Model Part Number Part Description Quantity
    IS 250 04007-32131 Fuel Pipe Sub-Assembly No. 2 1
    04007-32231 Fuel Pipe Sub-Assembly No. 3 1
    04007-33331 Fuel Pipe Gasket Kit (1) 1
    90430-08014 Gasket 2
    (1) For kit contents refer to section " XIII. APPENDIX  " on page 46. 
  • IS 350 
    PARTS INFORMATION (IS 350)

    Model Part Number Part Description Quantity
    IS 350 04007-32131 Fuel Pipe Sub-Assembly No. 2 1
    04007-32231 Fuel Pipe Sub-Assembly No. 3 1
    04007-33431 Fuel Pipe Gasket Kit (1) 1
    (1) For kit contents refer to section " XIII. APPENDIX  " on page 46. 

V. SAFETY PRECAUTIONS

A. PRECAUTIONS WHEN WORKING ON THE FUEL SYSTEM
CAUTION:
  • ALWAYS REMEMBER "SAFETY FIRST". 
  • BE EXTREMELY CAREFUL WHEN HANDLING FUEL TO PREVENT FIRES FROM OCCURRING. 
  • BEFORE REMOVING ANY FUEL SYSTEM PART, DRAIN ALL FUEL TO PREVENT SPILLING. 
  • BEFORE BEGINNING WORK ON THE FUEL SYSTEM, PERFORM THE FOLLOWING SAFETY CHECK LIST. 
B. SAFETY CHECKLIST
  1. AIR VENTILATION 
    • Perform work in a well ventilated area.
    • DO NOT  work underground or in an area where fuel vapors may fill the room due to poor ventilation.
    • Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
    • Dry all cloths that have come in contact with fuel in a well ventilated area and dispose of them properly (according to applicable local regulations).
      G07658683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED 
    • Fires and ignition sources are prohibited while working on the fuel system.
    • Clearly display the sign found on the next page stating "WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES". 
    • Smoking is prohibited near the work area.
    • DO NOT  work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
    • DO NOT  use work lamps or any other electrical appliance due to the risk of sparks flying from the power switch or a rise in temperature.
    • DO NOT  use metal hammers while working, due to the risk of flying sparks.
    • DO NOT  start any engine or perform any of the above in neighboring work bays.
      G07658684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. FIRE EXTINGUISHER 
    • Have a fire extinguisher ready and available before beginning work.
  4. PREVENT STATIC ELECTRICITY 
    • To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition.
    • Place appropriate warning cones or stand signs around the area as a caution.
      G07658685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07658686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07658687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. PRECAUTIONS WHEN USING A LIFT 
    • For bays equipped with auto lifts, cover all access cover joints with duct tape.
    • In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. Dissipate fuel vapors until the smell is gone.
      G07658688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. PREVENT THE FUEL FROM SPRAYING 
    • When disconnecting any fuel pipes or connectors there may still be some pressure remaining, even after discharging the system. To prevent the fuel from spraying, cover the pipe with a shop rag before disconnecting.
    • Remember to always wear protective goggles especially when disconnecting fuel pipes.
      G07658689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS 
    • Do not allow the fuel to come in contact with any parts made of rubber or leather.
      G07658690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. ASSIGN A SAFETY SUPERVISOR 
    • Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area.
  9. WORK SCHEDULING 
    • Work must be completed the same day.
    • As a general rule, do not stop work midway. If work must stop midway, inform your safety supervisor.
      G07658691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. WHEN CONNECTING THE FUEL PIPE 
    • Any amount of damage or small foreign object (dust, a piece of thread, rust, etc.) may cause a fuel leak. Be thorough when inspecting and cleaning the fuel pipes and seal surface areas.
      G07658692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

VII. FUEL PIPE REPLACEMENT

A. REPLACE FUEL PIPES NO. 2 AND NO. 3
G07658693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SEE VEHICLE DISASSEMBLY & REASSEMBLY WORK PROCEDURE BY MODEL SECTIONS FOR DETAILS ON VEHICLE DISASSEMBLY PRIOR TO PERFORMING FUEL PIPE REPLACEMENT. 

CAUTION:
  • WHEN REMOVING OR INSTALLING THE FUEL PIPES, PULL THEM UP IN A STRAIGHT LINE TO AVOID DAMAGE TO THE DELIVERY PIPE'S SEAL SURFACE, WHICH MAY LEAD TO A FUEL LEAK. 
  • SHIFTING THE FUEL PIPES EXCESSIVELY FROM LEFT TO RIGHT WHEN REMOVING THEM, MAY DAMAGE THE DELIVERY PIPE'S SEAL SURFACE, WHICH MAY LEAD TO A FUEL LEAK. 
    G07658694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REMOVE FUEL PIPE NO. 1 
    1. Disconnect the ignition coil connector shown in the illustration.
    2. Disconnect the 3 fuel hoses, and insert plugs into the hoses to prevent fuel from spilling onto the engine components.
    3. Remove the 2 bolts, and fuel pipe No. 1.
      NOTE: Clean up any spilled fuel with a shop rag or cloth.
      G07658695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE THE FUEL PRESSURE PULSATION DAMPER 
    1. Disconnect the fuel pressure pulsation damper connector.
      NOTE: To prevent damage to the connector, make sure to disconnect it prior to removing the fuel pressure pulsation damper.
      G07658696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST 09617-24011 (09612-24014) or a commercially available 22 mm crowfoot wrench, remove the fuel pressure pulsation damper and the 2 gaskets.
    3. Discard the 2 gaskets.
      NOTE:
      • Clean up any spilled fuel with a shop rag or cloth.
      • DO NOT damage the fuel return pipe when removing the fuel pulsation damper.
      • DO NOT forcefully remove the fuel pulsation damper, doing so will damage the seal surface.
      • DO NOT blow air into the fuel pressure damper, doing so will damage the internal diaphragm.
        G07658697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tape the fuel pump and fuel tube to prevent damage to them.
      G07658698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. DISCONNECT THE WATER HOSE JOINT 
    1. Remove the 2 bolts to disconnect the water hose joint.
      G07658699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION: WHEN REPLACING FUEL PIPE NO. 2, THE FUEL PUMP MUST BE REMOVED. THIS MUST BE DONE TO PREVENT SEAL DAMAGE AND THE TWISTING OF THE FUEL PIPE, FAILURE TO DO SO MAY RESULT IN A FUEL LEAK! 
  4. REMOVE THE FUEL PUMP AND FUEL PIPE NO. 2 
    1. Hold the fuel pump union bolt in place with a wrench, and loosen the fuel pipe fitting with a union/crowfoot nut wrench.
      NOTE:
      • There must be no free play in the union on the fuel pump side. If free play exist, replace the fuel pump.
      • Clean up any spilled fuel with a shop rag or cloth.
        G07658700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts from fuel pipe No. 2 (delivery side).
      NOTE: DO NOT remove fuel pipe No. 2 from the delivery pipe. ONLY remove the bolts.
      G07658701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts from the fuel pump assembly.
      G07658702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Move the water hose joint aside, and remove the fuel pump.
    5. Remove and discard the fuel pump insulator.
      NOTE:
      • Clean up any spilled fuel with a shop rag or cloth.
      • DO NOT use excessive force when moving the water hose joint aside.
        G07658703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tape the fuel pump opening to prevent foreign objects from entering.
      G07658704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FUEL PIPE NO. 2 
    IMPORTANT:

    Go to http://www.youtube.com/user/lemon2025Tips and type Lexus SSC 7LC into the Search Channel box to watch the video supplement to the next two steps. 

    1. Insert the two stud bolts (SST 04007-32331) to the delivery pipe's bolt attachment holes, and hand tighten.
      NOTE: Insert the stud bolts with the TORX® head facing up.
      G07658705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove fuel pipe No. 2 from the delivery pipe.
      NOTE: Clean up any spilled fuel with a shop rag or cloth.
      G07658706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT THE FUEL DELIVERY PIPE 
    1. Clean the delivery pipe seal surface, then inspect it as shown in the illustration for any damage.
      NOTE: If the seal surface was damaged, replace the delivery pipe to prevent the risk of a fuel leak.
      G07658707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION:

    WHEN INSTALLING FUEL PIPE NO. 2 AND THE FUEL PUMP, FOLLOW THE TEMPORARY INSTALLATION, TIGHTENING AND OTHER PROCEDURES SHOWN TO PREVENT DAMAGE TO ALL SEALING SURFACES. 

  7. REINSTALL THE FUEL PUMP AND INSTALL A NEW FUEL PIPE NO. 2 
    1. Place protective tape over the tapered section of the NEW  fuel pipe No. 2 to prevent damage.
      G07658708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply gasoline to the o-ring on the NEW  fuel pipe No. 2.
    3. Align the fuel pipe mounting holes with the stud bolts, and gently press the fuel pipe onto the delivery pipe by hand until there is no gap between them.
      G07658709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the protective tape from the fuel pump opening, and clean the mounting surface.
      G07658710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      IMPORTANT:

      Go to http://www.youtube.com/user/lemon2025Tips and type Lexus SSC 7LC into the Search Channel box to watch the video supplement below. 

    5. Turn the crankshaft until the flat part of the cam lobe is facing up through the fuel pump's attachment hole, as shown in the illustration.
    6. Pour 30 cc of engine oil through the fuel pump's attachment hole, and into the cylinder head oil collector.
      NOTE: This procedure makes the fuel pump and fuel pipe No. 2 installation easier.
      G07658711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Apply a coat of engine oil to the fuel pump camshaft lobe, and fuel pump lifter.
      G07658712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install a NEW  fuel pump insulator with the metal eyelets facing up.
    9. Move the water hose joint aside, and reinstall the fuel pump.
    10. Reinstall the 2 bolts.
      NOTE:
      • Make sure the metal eyelets of the NEW fuel pump insulator are facing up.
      • DO NOT use excessive force when moving the water hose joint aside.
        G07658713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the protective tape from the tapered section of the NEW  fuel pipe No. 2, and clean the mounting surface.
    12. Temporarily install fuel pipe No. 2 to the fuel pump.
      G07658714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Install the 2 fuel pump nuts, and torque them to specification.

      Torque Specification: 25 N.m (255 kgf.cm, 18 ft.lbf) 

      G07658715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the 2 stud bolts.
      G07658716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Clean the fuel pipe No. 2 (delivery side) bolt holes of dirt and gasoline.
    16. Reinstall the 2 bolts, and torque to specification.

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

      G07658717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Using a 19 mm union / crowfoot nut wrench, torque the fuel pipe fitting to specification.

      Torque Specification: 

      • Without a Union Nut Wrench: 30 N.m (306 kgf.cm, 22 ft.lbf) 
      • With a Union Nut Wrench: 25.7 N.m (262 kgf.cm, 19 ft.lbf) 
      NOTE:
      • Use a torque wrench with a fulcrum length of 180 mm (7.09 in).
      • The torque value above applies when the union nut / crowfoot wrench is parallel to the torque wrench.
        G07658718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. RECONNECT THE WATER HOSE JOINT 
    1. Reinstall the 2 bolts, and torque to specification.

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

      G07658719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REINSTALL THE FUEL PRESSURE PULSATION DAMPER 
    1. Remove the protective tape from the fuel pump and fuel tube, and clean their mounting surfaces.
    2. Install 2 NEW  gaskets, and reinstall the fuel pulsation damper by hand.
    3. Torque the fuel pulsation damper to specification using SST 09617-24011 (09612-24014) or a commercially available 22 mm crowfoot wrench.

      Torque Specification with SST: 

      With SST: 33 N.m (337 kgf.cm, 24 ft.lbf) 

      Without SST: 40 N.m (408 kgf.cm, 30 ft.lbf) 

      NOTE:
      • DO NOT use a fuel pulsation damper that has been dropped, as it may not work properly.
      • DO NOT blow air into the fuel pulsation damper. The air pressure may damage the internal diaphragm.
      • DO NOT damage the fuel return pipe when tightening the fuel pulsation damper.
      • Use a torque wrench with a fulcrum length of 260 mm (10.24 in).
      • The torque value above applies when the SST / crowfoot wrench is parallel to the torque wrench.
        G07658720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reconnect the fuel pressure pulsation damper connector.
      G07658721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REINSTALL FUEL PIPE NO. 1 
    1. Reinstall fuel pipe No. 1.
    2. Reinstall the 2 bolts and torque to specification.

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

    3. Remove the fuel hose plugs, and reconnect the 3 hoses.
    4. Reconnect the ignition coil connector.
      G07658722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL PIPE NO. 3 
    1. Remove the 4 bolts.
      G07658723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      IMPORTANT:

      Go to http://www.youtube.com/user/lemon2025Tips and type Lexus SSC 7LC into the Search Channel box to watch the video supplement to the next two steps. 

    2. Insert the two stud bolts (SST 04007-32331) to the delivery pipe's bolt attachment holes, and hand tighten.
      NOTE: Insert the stud bolts with the TORX® head facing up, and diagonally from each other as shown in the illustration.
      G07658724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove fuel pipe No. 3 from the delivery pipes.
      NOTE: Clean up any spilled fuel with a shop rag or cloth.
      G07658725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT THE FUEL DELIVERY PIPES 
    1. Clean the delivery pipes seal surfaces, and inspect them as shown in the illustration for any damage.
      NOTE: If the seal surface was damaged, replace the delivery pipe to prevent the risk of a fuel leak.
      G07658726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL A NEW FUEL PIPE NO. 3 
    IMPORTANT:

    Go to http://www.youtube.com/user/lemon2025Tips and type Lexus SSC 7LC into the Search Channel box to watch the video supplement to the steps below. 

    1. Apply gasoline to the o-rings on the NEW  fuel pipe No. 3.
    2. Align the fuel pipe mounting holes with the stud bolts.
      NOTE:
      • Make sure the fuel pipe No. 3 installation orientation is correct, as shown in the illustration.
      • DO NOT install the fuel pipe No. 3 backwards. If installed backwards it will interfere with the intake manifold.
        G07658727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Gently press the fuel pipe onto the delivery pipes evenly with both hands, as shown in the illustration, until there is no gap between them.
    4. Remove the 2 stud bolts.
    5. Clean the bolt holes of dirt and gasoline.
      NOTE: Do not discard the stud bolts, as they will be reused again.
      G07658728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      IMPORTANT:

      Go to http://www.youtube.com/user/lemon2025Tips and type Lexus SSC 7LC into the Search Channel box to watch the video supplement to the steps below. 

    6. Reinstall the 4 bolts, and torque to specification in the order shown in the illustration.

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

      G07658729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE ALL SHOP RAGS 
    NOTE: Before reinstalling the intake manifold, remove all shop rags.
    G07658730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION:
    • SEE VEHICLE DISASSEMBLY & REASSEMBLY WORK PROCEDURE BY MODEL SECTIONS FOR DETAILS ON VEHICLE REASSEMBLY. 
    • BE SURE TO CONDUCT THE LEAK TEST PROCEDURE AS SPECIFIED IN THE REASSEMBLY PROCEDURE. 

VIII. 2006 GS 300 - WORK PROCEDURE

A. REMOVE THE ENGINE COVERS AND DISCHARGE THE FUEL SYSTEM
G07658731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. CHECK FOR DTCs 
    1. If DTC(s) are present, verify them, view and record the freeze frame data, and perform the necessary repairs.
  2. REMOVE THE ENGINE ROOM COVER & V-BANK COVER SUB-ASSEMBLY 
    CAUTION:
    • DO NOT DISCONNECT ANY PART OF THE FUEL SYSTEM UNTIL YOU HAVE DISCHARGED THE FUEL SYSTEM PRESSURE. 
    • EVEN AFTER DISCHARGING THE FUEL SYSTEM PRESSURE, PLACE A PIECE OF CLOTH AROUND THE FITTINGS AS YOU SEPARATE THEM TO REDUCE THE RISK OF FUEL SPRAYING ON YOURSELF, IN THE ENGINE COMPARTMENT, AND ONTO OTHER PARTS. 
  3. DISCHARGE THE FUEL SYSTEM PRESSURE 
    1. Remove the relay block upper cover No. 2.
    2. Remove the fuel pump (F/PMP) 25 amp fuse.
    3. Start the engine.
    4. After the engine has stopped, turn the ignition switch OFF.
    5. Crank the engine again to check that it does not start.
      NOTE: DTC P0171/25 and/or P0191/49 may be set.
    6. Remove the fuel tank cap to discharge the fuel pressure.
    7. Record the radio station presets.
    8. Disconnect the negative (-) battery cable.
      NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed. The HDD navigation system requires approximately 6 minutes to save memory and settings, after turning OFF the ignition.
    9. Reinstall the fuel pump (F/PMP) 25 amp fuse.
    10. Reinstall the relay block upper cover No. 2.
      G07658732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
B. REMOVE THE INTAKE MANIFOLD
G07658733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REMOVE THE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt and air cleaner inlet.
  2. REMOVE THE AIR CLEANER CAP AND HOSE 
    1. Disconnect the MAF meter connector, and the wire harness from the clip.
    2. Disconnect the ventilation hose.
      G07658734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the VSV connector.
    4. Disconnect the fuel vapor feed hose from the VSV.
    5. Disconnect the fuel vapor hose from the throttle body.
      G07658735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Loosen the air cleaner hose clamp bolt.
    7. Unlatch the 4 air cleaner cap clips.
    8. Remove the air cleaner cap and hose.
      G07658736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE THE THROTTLE BODY ASSEMBLY 
    1. Disconnect the throttle body connector.
    2. Remove the 4 bolts, and move the throttle body assembly away from the intake air surge tank.
    3. Remove and discard the throttle body gasket.
      NOTE: DO NOT disconnect the 2 water hoses.
      G07658737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tape the intake air surge tank opening to prevent foreign objects from entering it.
      G07658738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCONNECT THE COLD START INJECTOR 
    1. Disconnect the cold start injector connector.
    2. Remove the bolt, the 2 washers and the fuel line.
    3. Discard the 2 washers.
      NOTE: DO NOT bend or damage the fuel line.
      G07658739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE THE INTAKE AIR SURGE TANK 
    1. Remove the clip.
      G07658740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the check valve hose from the intake air surge tank clip.
      G07658741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the wire harness clip from the intake air surge tank.
    4. Disconnect the intake air surge tank hose.
      G07658742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the IACV connector.
      G07658743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the wire harness clip from the intake air surge tank.
    7. Disconnect the water hose from the intake air surge tank.
      G07658744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 4 bolts from the intake air surge tank.
      G07658745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 nuts from the intake air surge tank.
    10. Using a long 5 mm hex socket, remove the 7 hex bolts from the intake air surge tank.
    11. Lift up the intake air surge tank and detach the DC Motor wiring harness clip.
    12. Remove the intake air surge tank.
    13. Remove and discard the intake air surge tank gasket.
      G07658746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE THE INTAKE MANIFOLD 
    1. Tape the intake manifold openings to prevent foreign objects from entering it.
    2. Disconnect the DC motor connector.
    3. Disconnect the SCV position sensor connector.
    4. Remove the 4 bolts and 4 nuts.
    5. Remove the intake manifold.
    6. Remove and discard the intake manifold gaskets.
      G07658747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Tape the cylinder head openings to prevent foreign objects from entering it.
      NOTE: PROCEED TO THE FUEL PIPE REPLACEMENT WORK PROCEDURE ON PAGE 10.
      G07658748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
C. REINSTALL THE INTAKE MANIFOLD
G07658749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. INSTALL THE INTAKE MANIFOLD 
    1. Remove the protective tape from the cylinder head openings, and clean the mounting surfaces.
    2. Install 2 NEW  gaskets.
    3. Reinstall the intake manifold.
    4. Reinstall the 4 bolts and 4 nuts, and torque to specification.

      Torque Specification: 21 N.m (214 kgf.cm, 15 ft.lbf) 

    5. Reconnect the SCV position sensor connector.
    6. Reconnect the DC motor connector.
      NOTE:
      • Make sure to align the intake manifold gasket with the shape of the cylinder head.
      • When installing the intake manifold, be careful not to damage the fuel injectors.
    7. Remove the protective tape from the intake manifold openings, and clean the mounting surfaces.
      G07658750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REINSTALL THE INTAKE AIR SURGE TANK 
    1. Install a NEW  gasket to the intake air surge tank.
    2. Reinstall the intake air surge tank, and reattach the DC Motor wiring harness clip.
    3. Using a long 5 mm hex socket, reinstall the 7 hex bolts, then reinstall the 2 nuts and torque to specification.

      Torque Specification: 

      Bolt: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Nut: 16 N.m (163 kgf.cm, 12 ft.lbf) 

      NOTE:
      • Make sure to align the intake air surge tank gasket.
      • Clean off any oil on the bolts or studs, failure to do so may result in over tightening of the fasteners.
      • DO NOT over tighten the attachment bolts for the plastic surge tank. Doing so may break the bolt.
        G07658751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reinstall the 4 bolts, and torque to specification in the order shown in the illustration.

      Torque Specifications: 

      Bolt A: 21 N.m (214 kgf.cm, 15 ft.lbf) 

      Bolt B: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07658752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Reconnect the water hose to the intake air surge tank clip.
    6. Reconnect the wire harness clip to the intake air surge tank.
      G07658753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Reconnect the IACV connector.
      G07658754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Reconnect the intake air surge tank hose.
    9. Reconnect the wire harness clip to the intake air surge tank.
      G07658755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Reconnect the check valve hose to the intake air surge tank.
      G07658756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Reinstall the clip.
      G07658757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. RECONNECT THE COLD START INJECTOR 
    1. Using 2 NEW  washers, reinstall the bolt to the cold start injector, and torque to specification.

      Torque Specification: 15 N.m (153 kgf.cm, 11 ft.lbf) 

    2. Reconnect the cold start injector connector.
      NOTE: DO NOT bend or damage the fuel line.
      G07658758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION:

    INSPECT FOR FUEL LEAKS. 

    Test the low pressure fuel pump within the fuel tank with the Toyota Techstream active test.  Fuel leakage can be quickly inspected, due to the low pressure fuel pump being dependent on the high pressure system.

    BEFORE CONNECTING THE BATTERY, DISSIPATE ALL FUEL VAPORS IN THE AREA. 

  4. RECONNECT THE NEGATIVE (-) BATTERY CABLE 
  5. INSPECT FOR FUEL LEAKS 
    1. "CHECK THE FUEL PUMP OPERATION AND TEST FOR FUEL LEAKS"  as outlined in the repair manual (TIS keyword: "3GR-FSE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION".)
  6. DISCONNECT THE NEGATIVE (-) BATTERY CABLE. 
    NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed. The HDD navigation system requires approximately 6 minutes to save memory and settings, after turning OFF the ignition.
  7. REINSTALL THE THROTTLE BODY ASSEMBLY 
    1. Remove the protective tape from the intake air surge tank opening, and clean the mounting surface.
    2. Install a NEW  throttle body gasket in the direction shown in the illustration.
      G07658759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Reinstall the throttle body assembly and the 4 bolts, then torque to specification.

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

    4. Reconnect the throttle body connector.
      G07658760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REINSTALL THE AIR CLEANER CAP AND HOSE 
    1. Reinstall the air cleaner cap and hose.
    2. Latch the 4 air cleaner cap clips.
    3. Tighten the air cleaner hose clamp bolt.
      G07658761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reconnect the fuel vapor hose to the throttle body.
    5. Reconnect the fuel vapor feed hose to the VSV.
    6. Reconnect the VSV connector.
      G07658762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Reconnect the ventilation hose.
    8. Reconnect the MAF meter connector, and the wire harness to the clip.
      G07658763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REINSTALL THE NO. 1 AIR CLEANER INLET 
    1. Reinstall the air cleaner inlet.
    2. Reinstall the bolt, and torque to specification.

      Torque Specification: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

D. INSPECT FOR FUEL LEAKS AND REINSTALL THE ENGINE COVERS
G07658764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REINSTALL THE FUEL TANK CAP 
  2. RECONNECT THE NEGATIVE (-) BATTERY CABLE 
  3. INSPECT FOR FUEL LEAKS 
    1. Prepare the vehicle for inspection by starting the engine, letting it run for approximately 5 seconds, and then shutting it off.
    2. Visually inspect ALL  fuel lines and connectors for leaks.
    3. If NO  leaks are found, re-inspect by repeating steps (a) and (b).
      NOTE: When preparing the vehicle for inspection the engine must be running. Cranking the engine alone may not start the high pressure fuel pump solenoids.
  4. REINSTALL THE V-BANK COVER SUB-ASSEMBLY & THE ENGINE ROOM COVERS 
  5. TEST DRIVE THE VEHICLE AND INSPECT FOR ABNORMALITIES, WARNING LIGHTS AND DRIVEABILITY ISSUES 
  6. INSPECT FOR DTCs AND REPAIR AS NECESSARY 
  7. REPROGRAM THE RADIO STATION PRESETS AND SET THE CLOCK TO THE APPROPRIATE TIME 
  8. PERFORM INITIALIZATION AND CALIBRATION OF THE VARIOUS VEHICLE SYSTEMS 
    1. Perform "INITIALIZATION"  as outlined in the repair manual (TIS keyword: "INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION").
      NOTE: Certain systems need to be initialized after reconnecting the negative (-) battery cable.

IX. 2006 IS 250 - WORK PROCEDURE

A. REMOVE THE ENGINE COVERS AND DISCHARGE THE FUEL SYSTEM
G07658765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. DTC CHECK 
    1. If DTC(s) are present, verify them, view and record the freeze frame data, and perform the necessary repairs.
  2. REMOVE THE ENGINE ROOM COVERS & V-BANK COVER SUB-ASSEMBLY 
    CAUTION:
    • DO NOT DISCONNECT ANY PART OF THE FUEL SYSTEM UNTIL YOU HAVE DISCHARGED THE FUEL SYSTEM PRESSURE. 
    • EVEN AFTER DISCHARGING THE FUEL SYSTEM PRESSURE, PLACE A PIECE OF CLOTH AROUND THE FITTINGS AS YOU SEPARATE THEM TO REDUCE THE RISK OF FUEL SPRAYING ON YOURSELF, IN THE ENGINE COMPARTMENT, AND ONTO OTHER PARTS. 
  3. DISCHARGE THE FUEL SYSTEM PRESSURE 
    1. Remove the relay block upper cover No. 2.
    2. Remove the fuel pump (F/PMP) 25 amp fuse.
    3. Start the engine.
    4. After the engine has stopped, turn the ignition switch OFF.
    5. Crank the engine again to check that it does not start.
      NOTE: DTC P0171/25 and/or P0191/49 may be set.
    6. Remove the fuel tank cap to discharge the fuel pressure.
    7. Record the radio station presets
    8. Disconnect the negative (-) battery cable.
      NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed. The HDD navigation system requires approximately 6 minutes to save memory and settings, after turning OFF the ignition.
    9. Reinstall the fuel pump (F/PMP) 25 amp fuse.
    10. Reinstall the relay block upper cover No. 2
      G07658766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
B. REMOVE THE INTAKE MANIFOLD
G07658767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REMOVE THE NO. 1 AIR CLEANER INLET 
    1. Remove the clip, the bolt and the air cleaner inlet.
  2. REMOVE THE AIR CLEANER CAP AND HOSE 
    1. Disconnect the MAF meter connector, and the wire harness from the clip.
    2. Disconnect the ventilation hose.
      G07658768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the vacuum hose from the clip.
      G07658769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Loosen the air cleaner hose clamp bolt.
    5. Unlatch the 4 air cleaner cap clips.
    6. Remove the air cleaner cap and hose.
      G07658770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE THE THROTTLE BODY ASSEMBLY 
    1. Disconnect the throttle body connector.
    2. Remove the 4 bolts, and move the throttle body assembly away from the intake air surge tank.
    3. Remove and discard the throttle body gasket.
      NOTE: DO NOT disconnect the 2 water hoses.
      G07658771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tape the intake air surge tank opening to prevent foreign objects from entering it.
      G07658772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCONNECT THE COLD START INJECTOR 
    1. Disconnect the cold start injector connector.
    2. Remove the bolt, the 2 washers and the fuel line.
    3. Discard the 2 washers.
      NOTE: DO NOT bend or damage the fuel line.
      G07658773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE THE INTAKE AIR SURGE TANK 
    1. Disconnect the VSV connector.
    2. Disconnect the fuel vapor feed hose from the VSV purge valve.
      G07658774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Disconnect the wire harness connector and hose from the intake air surge tank.
      G07658775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the intake air surge tank ventilation hose.
      G07658776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the 2 wire harness clips from the intake air surge tank.
    7. Disconnect the water hose from the intake air surge tank clip.
      G07658777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 3 bolts from the intake air surge tank.
      G07658778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 nuts from the intake air surge tank.
    10. Using a long 5 mm hex socket, remove the 6 hex bolts from the intake air surge tank.
    11. Lift up the intake air surge tank and detach the DC Motor wiring harness clip.
    12. Remove the intake air surge tank.
    13. Remove and discard the intake air surge tank gasket.
      G07658779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE THE INTAKE MANIFOLD 
    1. Tape the intake manifold openings to prevent foreign objects from entering it.
    2. Disconnect the DC motor connector.
    3. Disconnect the SCV position sensor connector.
    4. Remove the 4 bolts and 4 nuts.
    5. Remove the intake manifold.
    6. Remove and discard the gaskets.
      G07658780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Tape the cylinder head openings to prevent foreign objects from entering it.
      NOTE: PROCEED TO THE FUEL PIPE REPLACEMENT WORK PROCEDURE ON PAGE 10.
      G07658781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
C. REINSTALL THE INTAKE MANIFOLD
G07658782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REINSTALL THE INTAKE MANIFOLD 
    1. Remove the protective tape from the cylinder head openings, and clean the mounting surfaces.
    2. Install 2 NEW  gaskets.
    3. Reinstall the intake manifold.
    4. Reinstall the 4 bolts and 4 nuts, and torque to specification.

      Torque Specification: 21 N.m (214 kgf.cm, 15 ft.lbf) 

    5. Reconnect the SCV position sensor connector.
    6. Reconnect the DC motor connector.
    7. Remove the protective tape from the intake manifold openings, and clean the mounting surfaces.
      NOTE:
      • Make sure to align the intake manifold gasket with the shape of the cylinder head.
      • When installing the intake manifold, be careful not to damage the fuel injectors.
        G07658783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REINSTALL THE INTAKE AIR SURGE TANK 
    1. Install a NEW  gasket to the intake air surge tank.
    2. Reinstall the intake air surge tank, and reattach the DC Motor wiring harness clip.
    3. Using a long 5 mm hex socket, reinstall the 6 hex bolts, then reinstall the 2 nuts and torque to specification.

      Torque Specification: 

      Bolt: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Nut: 16 N.m (163 kgf.cm, 12 ft.lbf) 

      NOTE:
      • Make sure to align the intake air surge tank gasket.
      • Clean off any oil on the bolts or studs, failure to do so may result in over tightening of the fasteners.
      • DO NOT over tighten the attachment bolts for the plastic surge tank. Doing so may break the bolt.
        G07658784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reinstall the 3 bolts, and torque to specification in the order shown in the illustration.

      Torque Specifications: 

      Bolt A: 21 N.m (214 kgf.cm, 15 ft.lbf) 

      Bolt B: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07658785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Reconnect the water hose to the intake air surge tank clip.
    6. Reconnect the 2 wire harness clips to the intake air surge tank.
      NOTE: Make sure the water hose is positioned below the wire harness as shown in the illustration.
      G07658786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Reconnect the intake air surge tank ventilation hose.
      G07658787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Reconnect the wire harness connector and hose to the intake air surge tank.
    9. Reconnect the connector.
      G07658788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Reconnect the fuel vapor feed hose to the VSV purge valve.
    11. Reconnect the VSV connector.
      G07658789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT THE COLD START INJECTOR 
    1. Using 2 NEW  washers, reinstall the bolt to the cold start injector, and torque to specification.

      Torque Specification: 15 N.m (153 kgf.cm, 11 ft.lbf) 

    2. Reconnect the cold start injector connector.
      NOTE: DO NOT bend or damage the fuel line.
      G07658790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION:

    INSPECT FOR FUEL LEAKS. 

    Test the low pressure fuel pump within the fuel tank with the Toyota Techstream active test.  Fuel leakage can be quickly inspected, due to the low pressure fuel pump being dependent on the high pressure system.

    BEFORE CONNECTING THE BATTERY, DISSIPATE ALL FUEL VAPORS IN THE AREA. 

  4. RECONNECT THE NEGATIVE (-) BATTERY CABLE 
  5. INSPECT FOR FUEL LEAKS 
    1. "CHECK THE FUEL PUMP OPERATION AND TEST FOR FUEL LEAKS"  as outlined in the repair manual (TIS keyword: "FUEL (4GR-FSE) : FUEL SYSTEM: ON-VEHICLE INSPECTION".)
  6. DISCONNECT THE NEGATIVE (-) BATTERY CABLE. 
    NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed. The HDD navigation system requires approximately 6 minutes to save memory and settings, after turning OFF the ignition.
  7. REINSTALL THE THROTTLE BODY ASSEMBLY 
    1. Remove the protective tape from the intake air surge tank opening, and clean the mounting surface.
    2. Install a NEW  throttle body gasket in the direction shown in the illustration.
      G07658791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Reinstall the throttle body assembly and the 4 bolts, then torque to specification.

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

    4. Reconnect the throttle body connector.
      G07658792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REINSTALL THE AIR CLEANER CAP AND HOSE 
    1. Reinstall the air cleaner cap and hose.
    2. Latch the 4 air cleaner cap clips.
    3. Tighten the air cleaner hose clamp bolt.
      G07658793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reconnect the vacuum hose to the clip.
      G07658794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Reconnect the ventilation hose.
    6. Reconnect the MAF meter connector, and the wire harness to the clip.
      G07658795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REINSTALL THE NO. 1 AIR CLEANER INLET 
    1. Reinstall the air cleaner inlet.
    2. Reinstall the clip and the bolt, then torque to specification.

      Torque Specification: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

D. INSPECT FOR FUEL LEAKS AND REINSTALL THE ENGINE COVERS
G07658796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REINSTALL THE FUEL TANK CAP 
  2. RECONNECT THE NEGATIVE (-) BATTERY CABLE 
  3. INSPECT FOR FUEL LEAKS 
    1. Prepare the vehicle for inspection by starting the engine, letting it run for approximately 5 seconds, and then shutting it off.
    2. Visually inspect ALL  fuel lines and connectors for leaks.
    3. If NO  leaks are found, re-inspect by repeating steps (a) and (b).
      NOTE: When preparing the vehicle for inspection the engine must be running. Cranking the engine alone may not start the high pressure fuel pump solenoids.
  4. REINSTALL THE V-BANK COVER SUB-ASSEMBLY & THE ENGINE ROOM COVERS 
  5. TEST DRIVE THE VEHICLE AND INSPECT FOR ABNORMALITIES, WARNING LIGHTS AND DRIVEABILITY ISSUES 
  6. INSPECT FOR DTCs AND REPAIR AS NECESSARY 
  7. REPROGRAM THE RADIO STATION PRESETS AND SET THE CLOCK TO THE APPROPRIATE TIME 
  8. PERFORM INITIALIZATION AND CALIBRATION OF THE VARIOUS VEHICLE SYSTEMS 
    1. Perform "INITIALIZATION"  as outlined in the repair manual (TIS keyword: "INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION").
      NOTE: Certain systems need to be initialized after reconnecting the negative (-) battery cable.

X. 2006 IS 350 - WORK PROCEDURE

A. REMOVE THE ENGINE COVERS AND DISCHARGE THE FUEL SYSTEM
G07658797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. DTC CHECK 
    1. If DTC(s) are present, verify them, view and record the freeze frame data, and perform the necessary repairs.
  2. REMOVE THE ENGINE ROOM COVERS & THE V-BANK COVER SUB-ASSEMBLY 
    CAUTION:
    • DO NOT DISCONNECT ANY PART OF THE FUEL SYSTEM UNTIL YOU HAVE DISCHARGED THE FUEL SYSTEM PRESSURE. 
    • EVEN AFTER DISCHARGING THE FUEL SYSTEM PRESSURE, PLACE A PIECE OF CLOTH AROUND THE FITTINGS AS YOU SEPARATE THEM TO REDUCE THE RISK OF FUEL SPRAYING ON YOURSELF, IN THE ENGINE COMPARTMENT, AND ONTO OTHER PARTS. 
  3. DISCHARGE THE FUEL SYSTEM PRESSURE 
    1. Remove the relay block upper cover No. 2.
    2. Remove the fuel pump (F/PMP) 25 amp fuse.
    3. Start the engine.
    4. After the engine has stopped, turn the ignition switch OFF.
    5. Crank the engine again to check that it does not start.
      NOTE: DTC P0171/25 and/or P0191/49 may be set.
    6. Remove the fuel tank cap to discharge the fuel pressure.
    7. Record the radio station presets.
    8. Disconnect the negative (-) battery cable.
      NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed. The HDD navigation system requires approximately 6 minutes to save memory and settings, after turning OFF the ignition.
    9. Reinstall the fuel pump (F/PMP) 25 amp fuse.
    10. Reinstall the relay block upper cover No. 2.
      G07658798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
B. REMOVE THE INTAKE MANIFOLD
G07658799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REMOVE THE NO. 1 AIR CLEANER INLET 
    1. Remove the clip, the bolt and the air cleaner inlet.
  2. REMOVE THE AIR CLEANER CAP AND HOSE 
    1. Disconnect the MAF meter connector, and the wire harness from the clip.
    2. Disconnect the ventilation hose.
      G07658800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the vacuum hose from the clip.
      G07658801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Loosen the air cleaner hose clamp bolt.
    5. Unlatch the 4 air cleaner cap clips.
    6. Remove the air cleaner cap and hose.
      G07658802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE THE THROTTLE BODY ASSEMBLY 
    1. Disconnect the throttle body connector.
    2. Remove the 4 bolts, and move the throttle body assembly away from the intake air surge tank.
    3. Remove and discard the throttle body gasket.
      NOTE: DO NOT disconnect the 2 water hoses.
      G07658803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tape the intake air surge tank opening to prevent foreign objects from entering it.
      G07658804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE THE INTAKE AIR SURGE TANK 
    1. Disconnect the VSV connector.
    2. Disconnect the fuel vapor feed hose from the VSV purge valve.
      G07658805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the ventilation hoses.
      G07658806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 4 connectors.
    5. Disconnect the 2 wire harness clips from the intake air surge tank.
    6. Disconnect the water hose from the intake air surge tank clip.
      G07658807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the wire harness clip from the intake air surge tank.
      G07658808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 bolts from the intake air surge tank.
      G07658809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 nuts from the intake air surge tank.
    10. Using a long 5 mm hex socket, remove the 6 hex bolts from the intake air surge tank.
    11. Remove the intake air surge tank.
    12. Remove and discard the intake air surge tank gasket.
      G07658810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE THE INTAKE MANIFOLD 
    1. Tape the intake manifold openings to prevent foreign objects from entering it.
    2. Pinch and pull the fuel tube connector retainer to disconnect it from the delivery pipe.
      NOTE:
      • Use a rag over the fuel pipe to prevent leakage.
      • Clean up any spilled fuel with a shop rag or cloth.
      • Check for dirt, foreign matter and contaminants in and around the pipe and connector tube, and clean if necessary. Dirt, foreign matter and contaminants may damage the O-rings and cause fuel leaks in between the pipe and connector.
      • Do not use any tools to separate the pipe and connector.
      • Do not forcefully bend or twist the nylon fuel tube.
      • If the pipe and connector are stuck together, pinch the tube with your fingers and turn it carefully to free it, then disconnect the tube.
        G07658811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place a plastic bag over the fuel tube connector to prevent damage, to prevent foreign objects from entering it, and to prevent fuel from spilling out.
    4. Tape the fuel pipe to prevent damage and to prevent foreign objects from entering it.
      G07658812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and 4 nuts.
    6. Remove the intake manifold.
    7. Remove and discard the 2 intake manifold gaskets.
      G07658813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Tape the cylinder head openings to prevent foreign objects from entering it.
      NOTE: PROCEED TO THE FUEL PIPE REPLACEMENT WORK PROCEDURE ON PAGE 10.
      G07658814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
C. REINSTALL THE INTAKE MANIFOLD
G07658815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. INSTALL THE INTAKE MANIFOLD 
    1. Remove the protective tape from the cylinder head openings, and clean the mounting surfaces.
    2. Install 2 NEW  gaskets.
    3. Reinstall the intake manifold.
    4. Reinstall the 4 bolts and 4 nuts, and torque to specification.

      Torque Specification: 21 N.m (214 kgf.cm, 15 ft.lbf) 

      NOTE:
      • Make sure to align the intake manifold gasket with the shape of the cylinder head.
      • When installing the intake manifold, be careful not to damage the fuel injectors.
        G07658816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the plastic from the fuel tube connector.
    6. Remove the tape from the fuel pipe, and clean the attachment surfaces.
      NOTE:
      • Check the fuel tube connector and pipe for dirt, foreign objects and contaminants.
      • DO NOT forcefully bend or twist the nylon fuel tube.
        G07658817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Reconnect the fuel tube connector to the delivery pipe, and push the retaining clip in to lock the connector.
      NOTE: Check that the fuel tube and the delivery pipe are securely connected by pulling on them.
      G07658818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. After connecting the fuel tube, make sure the marks on the delivery pipes are lined up as shown in the illustration.
      G07658819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION:

    INSPECT FOR FUEL LEAKS. 

    Test the low pressure fuel pump within the fuel tank with the Toyota Techstream active test.  Fuel leakage can be quickly inspected, due to the low pressure fuel pump being dependent on the high pressure system.

    BEFORE CONNECTING THE BATTERY, DISSIPATE ALL FUEL VAPORS IN THE AREA. 

  2. RECONNECT THE NEGATIVE (-) BATTERY CABLE 
  3. INSPECT FOR FUEL LEAKS 
    1. "CHECK THE FUEL PUMP OPERATION AND TEST FOR FUEL LEAKS"  as outlined in the repair manual (TIS keyword: "FUEL (2GR-FSE) : FUEL SYSTEM: ON-VEHICLE INSPECTION".)
  4. DISCONNECT THE NEGATIVE (-) BATTERY CABLE. 
    NOTE: DO NOT disconnect the negative (-) battery cable until 6 minutes have elapsed. The HDD navigation system requires approximately 6 minutes to save memory and settings, after turning OFF the ignition.
  5. REINSTALL THE INTAKE AIR SURGE TANK 
    1. Remove the protective tape from the intake manifold openings, and clean the mounting surfaces.
    2. Install a NEW  gasket to the intake air surge tank.
    3. Reinstall the intake air surge tank.
    4. Using a long 5 mm hex socket, reinstall the 6 hex bolts, then reinstall the 2 nuts and torque to specification.

      Torque Specification: 

      Bolt: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Nut: 16 N.m (163 kgf.cm, 12 ft.lbf) 

      NOTE:
      • Make sure to align the intake air surge tank gasket.
      • Clean off any oil on the bolts and studs, failure to do so may result in over tightening of the fasteners.
      • DO NOT over tighten the attachment bolts for the plastic surge tank. Doing so may break the bolt.
        G07658820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Reinstall the 2 bolts, and torque to specification in the order shown in the illustration.

      Torque Specifications: 

      Bolt A: 21 N.m (214 kgf.cm, 15 ft.lbf) 

      Bolt B: 10 N.m (102 kgf.cm, 7 ft.lbf) 

      G07658821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Reconnect the wire harness clip to the intake air surge tank.
      G07658822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Reconnect the water hose to the intake air surge tank clip.
    8. Reconnect the 2 wire harness clips to the intake air surge tank.
    9. Reconnect the 4 connectors.
      NOTE: Make sure the water hose is positioned below the wire harness as shown in the illustration.
      G07658823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Reconnect the ventilation hoses.
      G07658824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Reconnect the fuel vapor feed hose to the VSV purge valve.
    12. Reconnect the VSV connector.
      G07658825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REINSTALL THE THROTTLE BODY ASSEMBLY 
    1. Remove the protective tape from the intake air surge tank opening, and clean the mounting surface.
    2. Install a NEW  throttle body gasket in the direction shown in the illustration.
      G07658826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Reinstall the throttle body assembly and the 4 bolts, then torque to specification.

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

    4. Reconnect the throttle body connector.
      G07658827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REINSTALL THE AIR CLEANER CAP AND HOSE 
    1. Reinstall the air cleaner cap and hose.
    2. Latch the 4 air cleaner cap clips.
    3. Tighten the air cleaner hose clamp bolt.
      G07658828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reconnect the vacuum hose to the clip.
      G07658829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Reconnect the ventilation hose.
    6. Reconnect the MAF meter connector, and the wire harness to the clip.
      G07658830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REINSTALL THE NO. 1 AIR CLEANER INLET 
    1. b) Reinstall the air cleaner inlet.
    2. c) Reinstall the clip and the bolt, then torque to specification.

      Torque Specification: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

D. INSPECT FOR FUEL LEAKS AND REINSTALL THE ENGINE COVERS
G07658831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REINSTALL THE FUEL TANK CAP 
  2. RECONNECT THE NEGATIVE (-) BATTERY CABLE 
  3. INSPECT FOR FUEL LEAKS 
    1. Prepare the vehicle for inspection by starting the engine, letting it run for approximately 5 seconds, and then shutting it off.
    2. Visually inspect ALL  fuel lines and connectors for leaks.
    3. If NO  leaks are found, re-inspect by repeating steps (a) and (b).
      NOTE: When preparing the vehicle for inspection the engine must be running. Cranking the engine alone may not start the high pressure fuel pump solenoids.
  4. REINSTALL THE V-BANK COVER SUB-ASSEMBLY & THE ENGINE ROOM COVERS 
  5. TEST DRIVE THE VEHICLE AND INSPECT FOR ABNORMALITIES, WARNING LIGHTS AND DRIVEABILITY ISSUES 
  6. INSPECT FOR DTCs AND REPAIR AS NECESSARY 
  7. REPROGRAM THE RADIO STATION PRESETS AND SET THE CLOCK TO THE APPROPRIATE TIME 
  8. PERFORM INITIALIZATION AND CALIBRATION OF THE VARIOUS VEHICLE SYSTEMS 
    1. Perform "INITIALIZATION"  as outlined in the repair manual (TIS keyword: "INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION"  ).
      NOTE: Certain systems need to be initialized after reconnecting the negative (-) battery cable.

XI. RECALLED PARTS DISPOSAL

As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused.

XII. APPENDIX

CALCULATING TORQUE WRENCH READINGS WHEN USING AND EXTENSION TOOL
  1. CALCULATING THE TORQUE WRENCH READING 
    1. When attaching a torque wrench to an SST or an extension tool, the actual tightening torque required will be greater.
    2. The torque wrench reading when using the required SST is listed in the repair manual and in this technical instruction. If the actual tool is different from the SST listed, calculate the torque wrench reading with the formula below.
    3. Formula: T'=T x L2 / (L1 + L2)
      TORQUE INFORMATION

      T' Torque Wrench Reading [N.m (f.cm)]
      T Required Torque [N.m (f.cm)]
      L1 SST or Length of Tool [cm]
      L2 Length of Torque Wrench [cm]
      G07658832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PARTS KIT CONTENTS
GS300 PARTS KIT CONTENTS

Part Number Part Description Quantity
04007-33231 Fuel Pipe Gasket Kit 1
The kit listed above includes the following parts: 
  • 17176-31020 = Gasket, Air Surge Tank to Manifold = Qty 1 
  • 17177-31020 = Gasket, Intake Manifold to Head = Qty 2 
  • 22271-31030 = Gasket, Throttle Body = Qty 1 
  • 23279-74010 = Gasket, Fuel Pressure Pulsation Damper = Qty 2 
  • 23915-46011 = Insulator, Fuel Pump = Qty 1 
IS250 PARTS KIT CONTENTS

Part Number Part Description Quantity
04007-33331 Fuel Pipe Gasket Kit 1
The kit listed above includes the following parts: 
  • 17176-31050 = Gasket, Air Surge Tank to Manifold = Qty 3 
  • 17177-31020 = Gasket, Intake Manifold to Head = Qty 2 
  • 22271-31030 = Gasket, Throttle Body = Qty 1 
  • 23279-74010 = Gasket, Fuel Pressure Pulsation Damper = Qty 2 
  • 23915-46011 = Insulator, Fuel Pump = Qty 1 
IS350 PARTS KIT CONTENTS

Part Number Part Description Quantity
04007-33431 Fuel Pipe Gasket Kit 1
The kit listed above includes the following parts: 
  • 17176-31060 = Gasket, Air Surge Tank to Manifold = Qty 1 
  • 17177-31060 = Gasket, Intake Manifold to Head = Qty 2 
  • 22271-31020 = Gasket, Throttle Body = Qty 1 
  • 23279-74010 = Gasket, Fuel Pressure Pulsation Damper = Qty 2 
  • 23915-46011 = Insulator, Fuel Pump = Qty 1 
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