Fuel System

1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.

HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery.
Therefore, if necessary. read the diagnosis before removing the terminal.

2. Do not smoke or work near an open flame when working on the fuel system.
3. Keep gasoline away from rubber or leather parts.

FUEL SYSTEM

1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures:
(a) Remove the luggage compartment trim cover.





(b) Disconnect the fuel pump connector.
(c) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK.
(d) Put a container under the connection.
(e) Slowly loosen the connection.
(f) Disconnect the connection.





(g) Plug the connection with a rubber plug.
(h) Reconnect the fuel pump connector.
(i) Reinstall the luggage compartment trim cover.
2. When connecting the flare nut or union bolt on the high pressure pipe union, observe the following procedures:

Union Bolt Type:





(a) Always use a new gasket.
(b) Tighten the union bolt by hand.
(c) Tighten the union bolt to the specified torque.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

Flare Nut Type:
(a) Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand.





(b) Using SST, tighten the flare nut to specified torque. SST 09631-22020

Torque: 34 N.m (347 kgf.cm, 25 ft.lbf)
27.2 N.m (277 kgf.cm, 20 ft.lbf) for SST

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





3. Observe the following precautions when removing and installing the injectors.
(a) Never reuse the O-ring.
(b) When placing a new O-ring on the injector, take care not to damage it in any way.
(c) Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil.





4. Install the injector to the delivery pipe and intake manifold as shown in the illustration.
5. Check that there are no fuel leaks after performing any maintenance anywhere on the fuel system.





(a) Connect the LEXUS hand-held tester to the DLC3.
(b) Turn the ignition switch ON and LEXUS hand-held tester main switch ON.

NOTICE: Do not start the engine.

(c) Select the ACTIVE TEST mode on the LEXUS hand-held tester.
(d) Please refer to the LEXUS hand-held tester operator's manual for further details.
(e) If you have no LEXUS hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.





(f) Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system.

NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack.

(g) Turn the ignition switch to LOCK.
(h) Disconnect the LEXUS hand-held tester from the DLC3.