TECHNICAL INSTRUCTIONS

TECHNICAL INSTRUCTIONS GS460 (for LHD) REPLACEMENT OF FUEL PRESSURE SENSOR GASKET 1. OPERATION FLOW CHART --------------------------------- 3 2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4 3. PREPARATION -------------------------------------------------- 5 4. WORK PROCEDURE ------------------------------------------- 7 1

Safety Precautions Be sure to observe the following precautions to prevent accidents and injuries. - Park the vehicle and chock the wheels. - If it is necessary to start the engine, perform the operation in a well ventilated area. - Before removing and reinstalling heavy parts such as the engine, transmission and differential using specified tools, check that there are no problems with the tools. - When working in a group of 2 or more, each person must work to ensure the safety of all team members. - To prevent burns and other injuries, use extra caution when handling parts that are subject to high temperatures, as well as rotating, sliding, or vibrating parts. - When lifting the vehicle using a jack, support it in the specified location using a safety stand. - When lifting the vehicle using a lift, lock the lift for safety. Also perform the following operation with care. Use of auto lift - Make absolutely certain that there are no other workers and no tools, parts, or other objects within the movable range of the lift. Also, be sure to announce all lift operations out loud (such as Raising the lift! and Lowering the lift! ) to alert other workers. - When raising or lowering the lift, pay attention to the positions of your arms, legs, and other body parts, and be extremely careful to prevent them from being caught in the lift. Use of brake cleaner - Use brake cleaner for appropriate purposes in accordance with instructions in the manual. - Do not use brake cleaner to remove dirt or stains from the engineer clothes and so forth, as it can catch on fire and cause serious burns. < Precautions > - Do not use brake cleaner near flames or fire. - Do not use large amounts of brake cleaner in a room where a fire is burning. - Do not keep brake cleaner in a place subject to high temperatures exceeding 40 C, such as a place subject to direct sunlight or near fire. - Do not put brake cleaner in fire. Edges - When handling the edges of parts and panels, wear protective gloves or apply protective tape to the edges to prevent injuries to your hands and fingers. 2

1. OPERATION FLOW CHART Check whether or not the vehicle has an affected VIN. No No further action is required. Yes Remove the vehicle components. Proceed to section E on page 19. Remove the fuel pressure sensor. Proceed to step 27 on page 38. Reinstall the fuel pressure sensor and the vehicle components. Proceed to section F on page 42. Return the vehicle to its original state and finish the work. 3

2. IDENTIFICATION OF AFFECTED VEHICLES 2.1. COVERED VIN RANGE Model Name VIN Range WMI VDS VIS BL1KS* *5003739~*5004244 GS460 JTH BL5KS* *5003834~*5003834 BL96S* *5000015~*5004224 Note: # indicates that various characters may occupy that position. Not all vehicles in these VIN ranges, are affected and/or sold in your country. For the detailed list of concerned vehicles, please refer to the attached VIN list. 2.2. VEHICLE IDENTIFICATION NUMBER LOCATION VIN is stamped on the cowl panel. It is also stamped on the certification label as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label 4

3. PREPARATION 3.1. Replacement components Parts: Part Name Part No. Qty Remarks REPLACEMENT KIT, FUEL PRSSURE SENSOR 04004-35138 1 GASKET FOR FUEL FILTER 90430-12026 1 GASKET, THROTTLE BODY 22271-50050 1 GASKET, INTAKE MANIFOLD TO HEAD 17171-38020 2 POLISHING BRUSH PAD 09264-99020 1 3.2. Replacement of Fuel Pressure Sensor Gasket Tools: Illustration Part Name Part No. Qty Remarks - Global Techstream - 1 For checking DTC - Torque Wrench - 1 - - E6 TORX Socket Wrench Pneumatic Ratchet Wrench For checking tightening torque - 1 For holding stud bolts - 1 For grinding the sensor installation surface - Air Blow Gun - 1 For cleaning Fuel Pressure Sensor Tool Set Delivery Pipe Polishing Tool Set 09260-99010 1 09264-99010 1 For tightening the fuel pressure sensor Delivery Pipe Polishing Tool (with Spare Velcro) Guide (with Protector) - 1-1 For grinding the sensor installation surfaces on the delivery pipe Angle Gauge Plate (For UR Engine) 09268-99040 1 24 mm Open End Wrench 09268-99050 1 For tightening the fuel pressure sensor Torque Wrench Adapter 09268-99060 1 Torque Wrench 09999-99040 1 5

Recommended Tool: Illustration Part Name Part No. Qty Remarks - PANDO39C - Appropriate quantity For pressure sensor threads Equipment: Part Name Part No. Qty Remarks Protective Gloves - Appropriate quantity For prevention of injury Protective Glasses - 1 For prevention of injury Protective Tape - Plastic Bag - Brake Cleaner - Heat Resistant Tape - Appropriate quantity Appropriate quantity Appropriate quantity Appropriate quantity For protection For protecting hose ends For cleaning and degreasing For installing the wiring harness protector Marker Pen - 1 Appropriate quantity Polishing Brush Pad - 2 For spare 6

4. WORK PROCEDURE <TABLE OF CONTENTS> A. WORK OUTLINE...8 B. NOTES REGARDING FUEL SYSTEM REPLACEMENT WORK...9 C. PRECAUTIONS FOR ALL OPERATIONS... 14 D. COMPONENTS... 16 E. REMOVE FUEL PRESSURE SENSOR... 19 F. REINSTALL FUEL PRESSURE SENSOR... 42 7

A. WORK OUTLINE Reinstall the fuel pressure sensor to the fuel delivery pipe using the specified procedure. Failure to observe the instructions will cause looseness or deformation of the sensor, and may result in abnormal sensor outputs. The vehicle does not need to be lifted up. Conventional Tightening Procedure <New Tightening Procedure> Grind and clean the sensor installation surface of the delivery pipe. (Remove all foreign objects including minute particles that cannot be detected by the naked eye.) Tighten the sensor to the specified torque (44 N*m) Apply lubrication to the threads to maintain constant friction coefficient, and tighten the sensor to the specified torque. As a preparation for tightening the sensor to the specified angle, tighten the sensor until the sensor, delivery pipe and gasket are tightened without any gap, to a point just before the gasket undergoes plastic deformation. Tighten the sensor to the specified angle. By applying the angle controlled tightening method, the gasket is plastically deformed to the desired amount, ensuring proper sealing performance. 8

<Make copies for use> B. NOTES REGARDING FUEL SYSTEM REPLACEMENT WORK CAUTIONS: When installing/uninstalling the fuel system components, keep safety first in mind and carefully observe the following instructions to avoid fire. Check each item in the appropriate section for each vehicle. 1. VENTILATION (a) Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or electric fans, because their motors might generate sparks. (b) Since it is possible for fuel vapor to build up, DO NOT work in or near a pit. (c) If fuel is spilled, use shop towels or similar material to quickly wipe it up and then use an air gun to diffuse the fuel vapor. (d) Shop towels and other materials that have come into contact with fuel should be dried in a well-ventilated area and then disposed of as appropriate. 2. DIFFUSION AND EXHAUST OF HIGHLY-CONCENTRATED FUEL VAPOR (a) Use compressed air frequently while working to prevent accumulation of high concentrations of fuel vapor. (b) When connecting battery terminals or operating switches, be sure to use compressed air to diffuse and ventilate fuel vapor. 3. USING GASOLINE AS AN ORGANIC SOLVENT (a) To prevent physical illness due to fuel vapor (organic solvent), use a gas mask for organic solvents as necessary in addition to ensuring natural ventilation. 9

<Make copies for use> 4. FLAMMABLE KEEP FIRE AWAY (a) When working on the fuel system, display the Flammable - Keep Fire Away sign. (Refer to the following page.) (b) Smoking is prohibited nearby. (c) Perform this work in an area where there are no flames due to nearby operation of welders, grinders, drills, electric motors, stoves, etc. (d) DO NOT use electrical devices such as operation indicators, because they can become hot and the operation of power switches can generate sparks. (e) DO NOT use iron or steel hammers while working, because they may generate sparks. (f) DO NOT perform the above operations or start engines even in adjacent stalls. 5. FIRE EXTINGUISHERS (a) Prepare fire extinguishers before starting this work. 6. PREVENTING STATIC ELECTRICITY (a) Keep the floor slightly wet but not wet enough to become slippery, to prevent the generation of static electricity. 7. HOLES IN THE FLOOR (a) If there are holes in the floor for lifts, etc., cover the gaps between service plates with tape, etc. (b) If fuel should get into a hole, remove the service plates to wipe away the fuel, and then use an air gun to dry the area until all fuel odor is gone. 10

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<Make copies for use> 8. PREVENTING FUEL SPLATTER (a) When disconnecting piping, a slight amount of pressure remains in the pipe even after performing fuel spill prevention work. Use a shop towel, etc. to prevent the splattering of fuel. (b) Wear protective eyewear when performing this work. 9. PROTECTION WHEN DISCONNECTING FUEL HOSES AND TUBES (a) Protect disconnected fuel tubes inside plastic bags, to prevent fuel spills, scratches, and contamination. 10. PRECAUTIONS FOR CONNECTING FUEL PIPES (a) Carefully clean and inspect fuel pipes, to prevent leakage due to small scratches or foreign matter (dust, lint, rust, etc.) in joints. 11. PREVENTING FUEL FROM COMING INTO CONTACT WITH PARTS (a) DO NOT allow fuel to come into contact with rubber or leather parts. 12

12. SAFETY MANAGER <Make copies for use> (a) Appoint a manger to be in charge of safety at all times. (b) The safety manager is in charge of constantly checking for flames and inspecting for safety around work areas. 13. SEPARATION OF WORK (a) This work must not be carried over to the next day. (b) In principle, work must not be interrupted. In cases where the interruption of work cannot be avoided, take care to perform all safety management procedures. 14. PREVENTING FUEL SPILLS INTO WATERWAYS (a) If a large volume of fuel is spilled, it must not be allowed to flow into waterways. It is extremely dangerous for fuel to spill into waterways or accumulate in sewage tanks, etc. 13

C. PRECAUTIONS FOR ALL OPERATIONS 1. PRECAUTIONS WHEN RAISING VEHICLE USING A LIFT OR JACK (a) Refer to the respective repair manual and follow the instructions within the Introduction section to ensure safety when working. (b) Ensure the safety of all personnel near the lift or jack, including yourself, before beginning work. Also announce all lift and jack operations out loud to prevent any personnel from being caught or harmed in any way. 2. WEAR PROTECTIVE GLASSES (a) Wear protective glasses when working under vehicle or where there is any risk of flying parts or debris. 3. DO NOT USE BRAKE CLEANER AS STAIN REMOVER (a) DO NOT spray brake cleaner onto any clothes since it is a flammable solvent that vaporizes easily. DO NOT use it near cigarettes or stoves as this can cause serious burns and injuries. 4. AVOID BURNS (a) If the engine is hot, wear protective gloves to prevent burns. 14

5. VEHICLE PROTECTION (a) A fender cover, a grill cover, seat covers, and protective tape, etc. must be used to protect the vehicle from dirt or scratches. NOTE: The protective measures listed above may not be shown in some illustrations to allow easy identification of the work location and to make the illustrations simple and easy to read. 6. HANDLING OF REMOVED PARTS (a) Destroy or mark and then store removed parts in a separate container so as to not be assembled again in error. (b) Check the removed parts when performing the completion inspection. NOTE: The parts shown in the illustration to the left are examples only and differ from the actual replacement parts. 7. DO NOT BREAK PARTS WHEN WORKING INSIDE ENGINE COMPARTMENT (a) DO NOT break parts by carelessly placing hands inside and leaning on the engine compartment while being preoccupied by work. 8. CHECK INSIDE ENGINE COMPARTMENT BEFORE ENGINE START-UP (a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left inside the engine compartment. 15

D. COMPONENTS 16

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E. REMOVE FUEL PRESSURE SENSOR 1. RECORD CUSTOMER SETTINGS (a) When the battery cable is disconnected, the settings for the audio, air conditioning, etc., may be reset. Therefore, before disconnecting the cable from the negative (-) battery terminal, make a note of the settings. 2. SWITCH TO RECIRCULATED AIR MODE (a) Turn the air conditioning to the recirculated air mode to prevent the entry of fuel vapor into the cabin. 3. CHECK FOR DTCS (a) If a DTC(s) is displayed, record the DTC and the freeze frame data and perform the repairs as necessary. 4. TAKE MEASURES AGAINST SECURITY OF NAVIGATION SYSTEM (a) In some cases, a user password is set for restart of the system after disconnection of the power supply. Obtain confirmation of the customer in advance regarding conditions of the system at the time of returning the vehicle to the customer. 5. WEAR PROTECTIVE GLOVES CAUTION: Wear protective gloves to prevent burns. 19

6. REMOVE ENGINE ROOM COVERS CAUTION: When removing the V-bank cover, DO NOT attempt to forcibly detach the front and rear clips at the same time as the cover may break. (a) Hold the V-bank cover sub-assembly at the rear with both hands and lift it upward to disengage the 2 clips on the rear of the cover. (b) Hold the V-bank cover sub-assembly at the front with both hands and lift it upward to disengage the 2 clips on the front of the cover, and remove the V-bank cover sub-assembly. (c) Remove the engine room side covers and cool air intake duct seal. 20

7. PREVENT FUEL LEAKAGE (a) Remove the No.2 relay block cover upper. (b) Disengage the claw and remove the F/PMP relay. (c) Disconnect the fuel pump register connector. 21

(d) Turn the engine switch on to start the engine. (e) Confirm that the engine stops automatically and then turn the engine switch off. NOTE: On some vehicles, it may take several minutes for the engine to stop. DTCs may be output. P0087: Fuel Rail / System Pressure Too Low P1603: Engine Stall History P1604: Startability Malfunction P1605: Rough Idling P0171: System Too Lean (Bank 1) P0174: System Too Lean (Bank 2) P0191: Fuel Pressure Sensor Signal Error P0230: Fuel Pump Primary Circuit (f) Crank the engine again and make sure that the engine does not start. 8. REMOVE FUEL TANK CAP ASSEMBLY CAUTION: DO NOT reinstall the cap until instructed, to prevent fuel leakage caused by a pressure rise inside the fuel tank. 9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal to prevent sparks. CAUTION: For models with a HDD navigation system, wait at least 6 minutes before disconnecting the battery. It takes approximately 6 minutes for the system to save information and settings after the engine switch is turned off. 22

10. RECONNECT FUEL PUMP REGISTER CONNECTOR 11. REINSTALL F/PMP RELAY 12. REINSTALL No.2 RELAY BLOCK COVER UPPER 13. DISPLAY NO FIRES SIGN (a) For safety, attach the NO FIRES sign on the vehicle in a place where it can be clearly seen. (Use a copy of the sign on the next page.) 23

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14. REMOVE No.1 AIR CLEANER INLET (a) Remove the bolt and the air cleaner inlet. 15. REMOVE AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE CAUTION: Remove the hose clamp and store it in a container. Otherwise it may fall off and become lost. 16. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 25

17. SEPARATE THROTTLE BODY ASSEMBLY CAUTION: DO NOT break parts by carelessly placing hands and leaning on the radiator hose or the surrounding components. (a) Disconnect the 2 connectors. (b) Remove the 4 bolts, and detach the throttle body. (c) Remove the gasket from the throttle body. (d) Destroy and store the removed gasket in a separate container so as not to reinstall it in error. (e) DO NOT completely remove but move the throttle body assembly to the side and place it on the reserve tank to provide work space. (f) Cover the opening with tape to prevent foreign material from entering into the intake manifold. 26

18. SEPARATE ENGINE WIRE HARNESS NOTE: Disconnect the wire harnesses to remove the engine manifold. (a) Remove the No.1 relay block cover upper. (b) Disengage the 2 clamps. (c) Remove the nut. (d) Disengage the 2 claws and separate the wire harnesses. 27

(e) Remove the 2 bolts, disconnect the connectors and disengage the clamps from the right side of the engine compartment. 28

(f) Remove the bolt and disengage the clamps from the left side of the engine compartment. 29

19. SEPARATE No.1 WIRING HARNESS PROTECTOR (a) Remove the heat resistant tape. (b) Disengage the 30 claws on the outer circumference of the No.1 wiring harness protector. CAUTION: DO NOT attempt to forcibly remove the protector by prying, as this could cause damage. (c) Disengage the claw and remove the upper protector. 30

(d) Remove the 4 nuts while holding the stud bolt with a E6 TORX socket wrench. CAUTION: Be sure to hold the stud bolt as the stud bolt will rotate together with the nuts, resulting in damage to the intake manifold. 20. REMOVE INJECTOR DRIVER AND BRACKET (a) Disconnect the 8 connectors. 31

(b) Detach the wire harness clamp. (c) Remove the 2 bolts and 2 nuts. (d) Lift the injector driver and detach the 2 wire harness clamps. 21. REMOVE No.1 ENGINE COVER 32

22. REMOVE No.1 FUEL PIPE CLAMP CAUTION: The clamp must be removed to prevent it from becoming damaged or broken during the removal of the intake manifold. 23. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY AND No.2 VENTILATION HOSE Be sure to observe the following procedure as instructed. Otherwise, coolant draining and air bleeding will later become necessary. (a) Remove the reserve tank cap. (b) Check the coolant level in the radiator reserve tank. If the level in the reserve tank is above the full level, drain the coolant using a dropper. CAUTION: If the coolant level in the reserve tank is above the full level, the coolant will overflow from the cap due to coolant from the hose. (c) Remove the 2 water hose sets. (d) Place a piece of cloth under the hoses as shown in the illustration. (e) Move the 2 clips. 33

(f) Slowly disconnect each of the 2 hoses while taking air into the hose. CAUTION: DO NOT disconnect the hose quickly as it may cause large amount of coolant to flow out. (g) Cover the ends of the hoses with plastic bags to prevent coolant leakage and entry of foreign material. (h) Disconnect the ventilation hose. (i) (j) Remove the 2 bolts. Move the 2 clips and disconnect the 2 hoses while lifting and holding the pipe at an angle. 34

(k) Reinstall the reserve tank cap. 24. REMOVE No.1 VACUUM SWITCHING VALVE ASSEMBLY AND HOSE (a) Disconnect the 2 hoses and the connector. (b) Remove the bolt and remove the vacuum switching valve and hose. CAUTION: Remove the 2 clips and store them in a container. Otherwise they may fall off and become lost. 25. REMOVE INTAKE MANIFOLD (a) Disconnect the ventilation hose. CAUTION: Remove the clip and store it in a container. Otherwise it may fall off and become lost. 35

(b) Disconnect the connector. (c) Remove the bolt from the wire harness bracket on the rear side of the intake manifold. (d) Remove the 8 bolts and 2 nuts. 36

(e) The main worker must remove the intake manifold from the vehicle right side while the assisting worker holds the wire harnesses up. (f) Remove the 2 gaskets from the intake manifold. (g) Destroy the removed gaskets and store them in a separate container so as not to reinstall them in error. 37

(h) Cover the openings with tape to prevent entry of foreign material into the cylinder heads. 26. REMOVE No.2 ENGINE COVER SUB-ASSEMBLY 27. REMOVE FUEL PRESSURE SENSOR (a) Disconnect the connector. NOTE: If the disconnection of the connector is difficult due to the orientation of the connector, loosen the pressure sensor by turning it 90 degrees. (b) Place more than enough pieces of cloth under the sensor to catch dripping fuel (approx. 100 ml). CAUTION: Prevent the fuel from dripping into the sponge between the banks of the engine. Otherwise, dripped fuel will penetrate into it, causing the fuel smell to remain inside the cabin. 38

(c) Wear protective glasses. Fuel could spray out into the air. (d) Attach the supplied torque wrench adapter to the supplied 24 mm open end wrench, and use them in combination to loosen the sensor as shown in the illustration. (e) Remove the sensor and gasket from the fuel delivery pipe. CAUTION: Handle the sensor with care as it will be reused. (f) Destroy the removed gasket and then store it in a separate container so as not to reinstall it in error. 39

40 CAUTION: DO NOT drop the sensor. If dropped, DO NOT reuse it but replace it with a NEW one.

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F. REINSTALL FUEL PRESSURE SENSOR 42

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1. GRIND SENSOR INSTALLATION SURFACE OF DELIVERY PIPE (a) Wear protective glasses. CAUTION: Be sure to wear protective glasses before grinding, to prevent metal chips and other debris from flying into your eyes. (b) Remove the guide (supplied) from the guide thread protector. CAUTION: DO NOT dispose of the protector as it will be necessary when the guide is stored. (c) Clean the threads of the guide and then tighten the guide into the sensor installation hole as far as possible by hand. CAUTION: Replace the guide with a NEW one if it cannot be inserted easily by hand. The threads in the guide may be damaged. (d) If the center piece of a NEW polishing brush pad (supplied together with a NEW sensor gasket) is left unremoved, remove it. CAUTION: DO NOT drop the removed piece of the pad into the engine compartment. 44

(e) Remove the pieces of cloth to prevent them from becoming entangled in the tool. (f) Set the NEW polishing brush pad onto the sensor seat surface. The pad can be installed in either direction. CAUTION: Always use a NEW polishing brush pad. (g) Attach the delivery pipe polishing tool set (supplied) to the pneumatic ratchet wrench. (h) Before turning on the pneumatic ratchet wrench, check that the polishing brush pad is in place. 45

(i) Ensure that the pneumatic ratchet rotates clockwise, and gently push the polishing tool against the polishing brush pad to grind the surface for approximately 10 seconds. CAUTION: DO NOT rotate the pneumatic ratchet counterclockwise as it may cause the guide to come out of the fuel delivery pipe. (j) Detach the polishing brush pad, and blow off the sensor installation surface thoroughly with compressed air. CAUTION: Thoroughly blow off the sensor installation surface with compressed air. In order to keep the sensor installation surface clean, DO NOT touch the surface after cleaning. (k) Remove the guide from the fuel delivery pipe. CAUTION: If the guide cannot be removed by hand, remove it using a tool such as a pair of pliers, while being extremely careful NOT to damage the sensor installation surface. (l) In order to protect the threaded portion, return the guide into the thread protector. 46

2. TIGHTEN FUEL PRESSURE SENSOR TO SPECIFIED TORQUE (a) Check a NEW gasket and the fuel pressure sensor for any damage or adhesion of foreign objects. (b) (b) Install the NEW gasket to the fuel pressure sensor. (c) Spray Pando 39C (supplied) all over the threaded portion of the sensor. CAUTION: DO NOT spray Pando 39C onto the connector. (d) Tighten the sensor onto the fuel delivery pipe by hand. 47 (e) Assemble the 24 mm open end wrench, torque wrench adapter and torque wrench (all supplied) so that they are in a straight line. CAUTIONS: DO NOT use any torque wrench other than the supplied torque wrench. If a click type torque wrench is used, the sensor may become overtorqued. The fuel pressure sensor cannot be tightened correctly if the tools are not in a straight line. The needle provided on the 24 mm open end wrench is not used when tightening the sensor to the specified torque.

(f) Tighten the sensor using the tools until the specified torque reading is obtained. Specified torque reading: T = 6.5 N m (66 kgf*cm, 58 in.*lbf) CAUTION: Hold the ball end of the torque wrench with your fingers and pull it to the direction of the arrow in the illustration to tighten the sensor to the specified torque. If the torque reading has exceeded the specified value, replace the sensor gasket with a NEW one, and then start over the procedure from 2 (b). (g) Remove the tools from the fuel pressure sensor. 3. TIGHTEN FUEL PRESSURE SENSOR TO SPECIFIED ANGLE (a) Remove the 2 bolts, indicated by the arrows in the illustration, from the fuel delivery pipe. 48

(b) Detach the 2 fastening bolts from the bolt holders of the supplied angle gauge plate. (c) Set the angle gauge on the delivery pipe and tighten the 2 angle gauge fastening bolts with a tool until the gauge is secure. (d) Set the 24 mm open end wrench to the fuel pressure sensor with the needle tip of the open end wrench close to the zero position of the angle gauge plate. CAUTION: If the fuel pressure sensor is unintentionally rotated, replace the gasket with a NEW one, and then start over the procedure from 2 (b). (e) Set the torque wrench adapter to the 24 mm open end wrench. 49

(f) Eliminate excessive play in the tools and clearance with the sensor by lightly pulling the torque wrench adapter to the sensor tightening direction with your fingers, and then gently hold it in place. CAUTION: Use only 1 or 2 fingers when eliminating excessive play and clearance, to prevent rotating the sensor by applying excessive force. If the fuel pressure sensor is unintentionally rotated, replace the sensor gasket with a NEW one, and then start over the procedure from 2 (b). NOTE: If the excessive play and clearance is not eliminated in this step, the sensor cannot be tightened exactly as required in the later process. 50

(g) While holding the tools with excessive play and clearance eliminated, gently move the needle of the 24 mm open end wrench until the needle tip comes into contact with the zero position of the angle gauge plate. CAUTION: If the fuel pressure sensor is unintentionally rotated, replace the sensor gasket with a NEW one, and then start over the procedure from 2 (b). 51

(h) The main worker must tighten the sensor until the needle tip comes to the center of the specified angle range while the assisting worker is visually checking the positions of the needle tip from the front of the angle gauge. CAUTION: If the sensor is tightened beyond the specified angle range, replace the sensor gasket with a NEW one, and then start over the procedure from 2 (b). When checking the positions of the needle tip, it must be seen from the front of the angle gauge. (i) Remove the tools from the fuel pressure sensor. 52

(j) Remove the 2 fastening bolts from the angle gauge plate, and then remove the plate. (k) Reinstall the 2 bolts to the fuel delivery pipe. Specified torque: T = 21 N*m (214 kgf*cm, 15 ft.*lbf) (l) Return the fastening bolts of the angle gauge plate to their holders. (m) Reconnect the connector. 53

4. CHECK INSIDE ENGINE COMPARTMENT (a) Blow compressed air in the engine compartment until smell of gasoline is gone. (b) Check that no tools or pieces of cloth are left inside the engine compartment. 5. REINSTALL No.2 ENGINE COVER SUB-ASSEMBLY 6. REINSTALL INTAKE MANIFOLD (a) Remove the protective tape and clean the installation surfaces. (b) Install 2 NEW gaskets. 54

(c) The main worker must temporarily place the intake manifold to the installation position while the assisting worker holds the wire harnesses up. 55

(d) Tighten the 8 bolts and 2 nuts to the specified torque, in the sequence shown in the illustration. Specified torque: T = 21 N m (214 kgf*cm, 15 ft.*lbf) (e) Reinstall the bolt to the wire harness bracket on the rear side of the intake manifold. Specified torque: T = 12 N m (122 kgf*cm, 9 ft.*lbf) (f) Reconnect the connector. (g) Reconnect the ventilation hose. 56

7. REINSTALL No.1 VACUUM SWITCHING VALVE ASSEMBLY AND HOSE (a) Reinstall the No.1 vacuum switching valve and hose with the bolt. Specified torque: T = 21 N m (214 kgf*cm, 15 ft.*lbf) (b) Reconnect the 2 hoses and the connector. (c) Reinstall the 2 clips. 8. REINSTALL WATER BY-PASS PIPE SUB-ASSEMBLY AND No.2 VENTILATION HOSE (a) Reinstall the hoses by reconnecting the 5 sections. (b) Reinstall the pipe with the 2 bolts. Specified torque: T = 10 N m (102 kgf*cm, 7 ft.*lbf) (c) Reinstall the 2 water hose sets. 9. REINSTALL No.1 FUEL PIPE CLAMP 57

10. REINSTALL No.1 ENGINE COVER 11. REINSTALL INJECTOR DRIVER AND BRACKET (a) Reinstall the injector driver with the 2 bolts and 2 nuts. Specified torque: T = 10 N m (102 kgf*cm, 7 ft.*lbf) (b) Re-engage the wire harness clamp. (c) Re-engage the 2 wire harness clamps. 58

(d) Reconnect the 8 connectors. 12. REINSTALL No.1 WIRING HARNESS PROTECTOR (a) Reinstall the wiring harness protector with the 4 nuts. Specified torque: T = 10 N m (102 kgf*cm, 7 ft.*lbf) (b) Re-engage the claw and the 30 claws on the protector. 59

(c) Wrap heat resistant tape around the portion shown in the illustration. CAUTION: DO NOT apply tape to the wire harness. 60

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13. RECONNECT ENGINE WIRE HARNESS (a) Reinstall the 2 bolts, reconnect the connectors and re-engage the clamps in the right side of the engine compartment. 62

(b) Reinstall the bolt and re-engage the clamps in the left side of the engine compartment. 63

(c) Re-engage the 2 claws and reconnect the wire harness. (d) Reinstall the nut. Specified torque: T = 12 N m (122 kgf*cm, 9 ft.*lbf) (e) Re-engage the 2 clamps. (f) Reinstall the No.1 relay block cover upper. 14. REINSTALL THROTTLE BODY ASSEMBLY (a) Remove the protective tape from the intake manifold, and then clean the surfaces where the throttle body will be installed. (b) Install a NEW gasket. (c) Clean the throttle body assembly. (d) Reinstall the throttle body assembly with the 4 bolts. Specified torque: T = 10 N m (102 kgf*cm, 7 ft.*lbf) (e) Reconnect the 2 connectors. 64

15. REINSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 16. REINSTALL AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE 17. REINSTALL No.1 AIR CLEANER INLET (a) Reinstall the air cleaner inlet with the bolt. Specified torque: T = 5.0 N*m (51 kgf*cm, 44 in.*lbf) 65

18. REINSTALL FUEL TANK CAP ASSEMBLY 19. RECONNECT CABLE TO NEGATIVE BATTERY TERMINAL 20. CHECK INSIDE ENGINE COMPARTMENT (a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left inside the engine compartment. 66

21. REMOVE NO FIRES SIGN 22. CHECK AND CLEAR DTCS 23. CHECK FOR COOLANT LEAKAGE 24. INSPECT THROTTLE BODY ASSEMBLY OPERATION (a) Start the engine and check that the Check Engine Warning Light is off. (b) Wait until the engine warms up, then turn the air conditioning off and check that the engine idling speed is within the standard range. Standard: 700 to 800 rpm CAUTION: Power to all accessories, air conditioning and electric fans must be turned off, and the shift lever must be in the N or P position during the operational inspections. (c) Quickly depress the accelerator pedal to its full travel and confirm that the [Powertrain / Engine / Data List / All Data / Throttle Sensor Position] displayed on the Techstream is not lower than 60%. 25. PERFORM DRIVING TEST 26. RESTORE SETTINGS AFTER RECONNECTING CABLE TO NEGATIVE BATTERY TERMINAL Restore the data which was recorded before the battery terminal cable was disconnected. Power window control system (Production period: January 2005 through September 2007) Sliding roof system (Production period: January 2005 through September 2007) Parking assist monitor system Lexus parking assist-sensor system Variable gear ratio steering system 27. REINSTALL ENGINE ROOM COVERS 67