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Home › Lexus › 2003 › LS 430 › Repair and Diagnosis › External Pages › Different car › Section 450 (Engine Fuel System (2UZ-FE)) › Fuel System Precaution

Fuel System Precaution

WARNING: This page is about a different car, the 2003 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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.
  2. WORK TO PREVENT GASOLINE FROM SPILLING OUT 
    CAUTION:
    • Perform disconnecting operation of the fuel system parts after working for prevent gasoline form spilling out.
    • As there is remained pressure in the fuel line after working for prevent gasoline from spilling out, prevent it from splashing inside the vehicle compartment by covering them with a shop rag.
    1. Remove the circuit opening relay in the engine room relay block.
      Fig 1: Identifying C/OPN Relay
      G02812680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. NOTE:

      There is a case that DTC P0171 (system to lean) is output.

    2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
    3. Check that the engine does not start.
    4. Remove the fuel tank cap, and let the air out of the fuel tank.
    5. Disconnect negative (-) terminal cable from battery.
    6. Reinstall the circuit opening relay.
  3. FUEL SYSTEM 
    1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures.
      1. Work for prevent gasoline from spilling out.
      2. Disconnect the fuel pump tube.

        (See Step 6 in Removal & Installation and Disassembly & Reassembly under FUEL TANK ASSY article.)

      3. Drain the fuel remaining inside the fuel pump tube.
      4. Prevent the disconnected fuel pump tube from damaging and mixing foreign objects by covering them with a vinyl bag.
        Fig 2: Covering Fuel Pump Tube With Vinyl Bag
        G02812681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Put a container under the connection.
    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.
        Fig 3: Connecting Union Bolt (Fuel Pressure Pulsation Damper) On High Pressure Pipe Union
        G02812682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Tighten the union bolt by hand.
        3. NOTE:

        Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

        Fig 4: Tightening Union Bolt To Specified Torque
        G02812683Courtesy 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) 

    3. Observe these precautions when removing and installing the injectors.
      1. Never reuse the O-ring.
      2. When placing the new O-rings on the injector, take care not to damage it in any way.
        Fig 5: Observing Precautions When Removing And Installing Injectors
        G02812684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Coat new O-rings with spindle oil or gasoline before installing. Never use engine, gear or brake oil.
      4. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or cylinder head touches an O-ring of the injector.
      Fig 6: Installing Injector To Delivery Pipe And Lower Intake Manifold
      G02812685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the injector to the delivery pipe and lower intake manifold, as shown in the illustration.
    5. Observe these precautions when disconnecting the fuel tube connector (Quick type A):
      1. Remove the fuel pipe clamp No. 1.
        Fig 7: Observing Precautions When Disconnecting Fuel Tube Connector (Quick Type A)
        G02812686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.
      3. Check that there is any dirt like mud in the pipe and around the connector before disconnecting them and clean the dirt away.
      4. Be sure to disconnect them with hands.
      5. When the connector and the pipe are stuck, pinch the fuel pipe between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time.
        Fig 8: Disconnecting Quick Connector Type A
        G02812687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.
      7. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
    6. Observe these precautions when connecting the fuel tube connector (Quick Type A):
      1. Check that there is any damage or foreign objects in the connected part of the pipe.
      2. Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply little amount of fresh engine oil on the tip of the pipe.
        Fig 9: Reconnecting Fuel Tube Connector (Quick Type A)
        G02812688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
        Fig 10: Confirming Quick Type A Connection
        G02812689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Check that there is any fuel leak.
    7. Observe these precautions when disconnecting the fuel tube connector (Quick type B):
      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 is out. Do not use any tool at this time.
        Fig 11: Disconnecting Fuel Tube Connector (Quick Type B)
        G02812690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    8. Observe these precautions when connecting the fuel tube connector (Quick type B):
      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.
        Fig 12: Connecting Fuel Tube Connector (Quick Type B)
        G02812691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
        Fig 13: Checking Pipe And Connector Are Securely Connected (Quick Type B)
        G02812692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Check if there is any fuel leakage.
    9. 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 connection 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.
  4. CHECK FUEL LEAK 
    1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (See ON-VEHICLE INSPECTION )
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