Lexus LX 4.5 V8 Diesel 1VD-FTV (2017): Fuel Injector Replacement

Part numbers are from the manufacturer's original catalogue. Check them against your VIN before ordering.

• torque wrench (5-60 N·m range)
• socket and wrench set
• split (flare nut) high-pressure line wrench
• injector puller (as needed)
• caps and clean plugs for fittings
• non-acid cleaner
• compressed air
• Techstream-level diagnostic scan tool or equivalent with injector registration function

1. Before starting, make sure the replacement is really needed: use a scan tool to check the per-cylinder corrections (balance, return flow), compression, and any injector-related fault codes. This keeps you from replacing good parts when the real problem is the high-pressure pump, the fuel filter, or air in the system.
2. Disconnect the negative battery terminal and wait at least 10 minutes. Do not work on a hot engine. Relieve the residual pressure in the fuel system. Do not disconnect high-pressure lines on a running or recently stopped engine.
3. Thoroughly wash and blow off the top of the engine, especially around the injectors, the rail, and the fuel lines. Any dirt that gets into open passages will ruin the new injectors.
4. Remove the decorative covers, air ducts, intercooler pipes, and any intake tract components that get in the way. Disconnect the sensor connectors and wiring harnesses, and take photos of how they are routed. Drain some of the coolant if you will need to disconnect hoses along the way.
5. Remove the valve covers from both cylinder heads (loosen the fasteners evenly, in sequence). Replace the cover gaskets during reassembly. Immediately cover the open cavities with a clean, lint-free cloth.
6. Disconnect the injector electrical connectors and label them by cylinder. Loosen the high-pressure lines with the split wrench, and do not bend or rock the lines. Immediately cap the rail and injector fittings.
7. Disconnect the injector return (leak-off) lines. Replace the clips and clamps with new ones if they are damaged or have lost their spring tension.
8. Remove the fasteners of the injector hold-down clamps and carefully lift the injectors straight out, without tilting them. If an injector is stuck from carbon buildup, use a slide-hammer puller or a dedicated tool. Do not strike the body or twist it in its bore.
9. Remove the old sealing washers from the bores (a washer may remain at the bottom of the well). Clean the injector bores in the cylinder head with a dedicated tool and a soft mandrel, without letting carbon fall into the cylinder. Inspect the seat: it must have no scoring or signs of combustion gas leakage.
10. Install new sealing washers, and lubricate only what the injector manufacturer specifies, using only an approved compound. Insert the injector straight, without tilting, and secure it with the clamp. Tighten the clamp fasteners evenly in two stages to the Lexus/Toyota specification for the 1VD-FTV (approximately 20-30 N·m (15-22 lb-ft); check the exact value against the factory manual).
11. Install the high-pressure lines: first finger-tight until the threads bottom out, then tighten with the split wrench to the factory torque (approximately 25-40 N·m (18-30 lb-ft) depending on the line; check the exact value against the factory manual). Do not overtighten, as this damages the cone seat and causes leaks under pressure.
12. Connect the return lines and electrical connectors according to your marks, reassemble the valve covers with new gaskets (cover torque per the factory manual, usually low, about 8-12 N·m (71-106 lb-in)), and reinstall the intake tract and covers. Reconnect the battery.
13. Register the new injectors in the ECM with the diagnostic scan tool: enter the individual codes (QR or ID codes printed on the body of each injector) strictly by cylinder. Without this procedure, the engine will run roughly, smoke, and may set fault codes.
14. Prime the fuel system according to the procedure (hand pump or scan tool mode), then start the engine and let it idle. Inspect all connections for fuel leaks. Check for fault codes and, if necessary, perform the fuel correction learning procedure and a test drive.

• The high-pressure fuel system is dangerous: a jet of diesel fuel under pressure can penetrate the skin
• Do all work only with the engine off and cool, after relieving the pressure
• Cleanliness is critical, since even the smallest particles can ruin the injectors
• Without registering the new injector codes, the engine will not run properly
• If you have no experience with common rail systems and do not have the right scan tool, leave the job to a repair shop