Fuel Tank: Service Precautions
WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury:- Keep a dry chemical (Class B) fire extinguisher near the work area.
- Place a "CAUTION FLAMMABLE" sign in the work area.
- Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away.
- Wear eye protection.
- Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).
- Relieve the fuel system pressure prior to disconnecting fuel system components.
- Disconnect the negative battery cable except for tests where battery voltage is required.
- Use a suitable container to store or catch fuel.
- Do not replace fuel pipe with fuel hose.
- Plug all disconnected fuel line fittings and hoses.
- After making any fuel system repairs ALWAYS inspect for fuel leaks.
FUEL SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. WORK FOR PREVENT GASOLINE FROM SPILLING OUT
a. Disconnect the fuel pump connector.
b. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
c. Disconnect negative (-) terminal cable from battery.
d. Connect the fuel pump connector.
5. FUEL SYSTEM
a. 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.
b. 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.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque:
33 Nm (340 kgf.cm, 24 ft.lbf) for use with SST
39 Nm (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. 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 Nm (330 kgf.cm, 24 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. 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.
e. 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.
f. 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.
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.
g. 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.
h. 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.
6. CHECK FUEL LEAK
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.