Fuel System: Precaution

BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM
KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
WORK FOR PREVENT GASOLINE FROM SPILLING OUT
1. Disconnect the fuel pump connector.
2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
3. Disconnect negative (-) terminal cable from battery.
4. Connect the fuel pump connector.
FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures.
  1. Work to prevent gasoline from spilling out.
  2. Disconnect the fuel tube.
  3. Drain the fuel remained inside the fuel tube.
  4. Protect the disconnected fuel tube from damage and foreign material by covering it with a plastic bag.
  5. Put a container under the connection.
    
    Fig 1: Disconnecting Fuel Pump Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures:
  1. Always use 2 new gaskets.
  2. Tighten the union bolt by hand.
    
    Fig 2: Connecting Union Bolt On High Pressure Pipe Union
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using SST, tighten the union bolt to the specified torque.
    SST 09612-24014 (09617-24011)
    
    Torque:
    
    33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST
    
    39 N.m (400 kgf.cm, 29 ft.lbf)
    
    HINT:
    
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    
    Fig 3: Identifying Fulcrum Length
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. When connecting the flare nut on the high pressure pipe union, observe these procedures:
  1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand.
  2. Using SST, tighten the flare nut to the specified torque.
    SST 09023-38400
    
    NOTE: Do not rotate the fuel main tube, when tightening the flare nut.
    
    Torque: 32 N.m (330 kgf.cm, 24 ft.lbf)
    
    HINT:
    
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    
    Fig 4: Tightening Flare Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe these precautions when removing and installing the injector.
  1. Never reuse the O-ring.
  2. When placing a new O-ring on the injector, take care not to damage it in any way.
  3. Coat a new O-ring with spindle oil or gasoline before installing. Never use engine, gear or brake oil.
    
    Fig 5: Identifying Correct Way Of Installing O-Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector.
6. Observe these precautions when disconnecting the fuel tube connector (quick type):
  1. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.
  2. Be sure to disconnect with hands.
    
    Fig 6: Disconnecting Fuel Tube Connector (Quick Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. When the connector and the pipe are stuck, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time.
  4. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.
  5. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
    
    Fig 7: Disconnecting Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Observe these precautions when connecting the fuel tube connector (quick type):
  1. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe.
  2. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
  3. Check if there is any fuel leakage.
    
    Fig 8: Checking Pipe Connections
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Observe these precautions when handling nylon tube.
  1. Pay attention not to turn the connected part of the nylon tube and the quick connector with force when connecting them.
  2. Pay attention not to kink the nylon tube.
  3. Do not remove the EPDM protector on the outside of the nylon tube.
  4. Must not close the piping with the nylon tube by bending it.
    
    Fig 9: Checking Pipe Connections
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FUEL LEAK
1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
  1. Connect the LEXUS hand-held tester to the DLC3.
  2. Turn the ignition switch ON and LEXUS hand-held tester main switch ON.
    NOTE: Do not start the engine.
  3. Select the active test mode on the LEXUS hand-held tester.
  4. Please refer to the LEXUS hand-held tester operator's manual for further details.
  5. If you have no LEXUS hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.
  6. Check that there are no leaks from any part of the fuel system.
  7. Turn the ignition switch to LOCK.
  8. Disconnect the LEXUS hand-held tester from the DLC3.
    
    Fig 10: Connecting Lexus Hand-Held Tester To DLC3
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002