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Precaution [04/2013 - 08/2015]

WARNING: This page is about a different car, the 2015 Lexus IS 250 and 2014 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. BEFORE WORKING ON FUEL SYSTEM 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
      NOTE:

      After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work.

      Refer to PRECAUTION [04/2013 - 08/2015]

    2. Do not smoke or work near fire when handling the fuel system.
    3. Keep fuel away from rubber or leather parts.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.
    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
    • Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.
    1. When discharging fuel system pressure by disconnecting the FUEL PUMP (20A) fuse:
      1. Remove the No. 1 engine room relay block and No. 1 junction block assembly cover.
      2. Remove the FUEL PUMP (20A) fuse.
      3. Start the engine. After the engine has stopped on its own, turn the engine switch off.
        NOTE:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

      4. Crank the engine again and make sure that the engine does not start.

        HINT: 

        DTC P0171/P0174 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) or P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Refer to DTC CHECK / CLEAR [04/2013 - 08/2015]

      5. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      6. Disconnect the cable from the negative (-) battery terminal.
        NOTE:

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

        Refer to INITIALIZATION [04/2013 - 06/2014] , or refer to INITIALIZATION [06/2014 - 08/2015]

      7. Install the FUEL PUMP (20A) fuse.
      8. Install the No. 1 engine room relay block and No. 1 junction block assembly cover.
    2. When discharging fuel system pressure by disconnecting the fuel pump connector:
      1. Remove the rear seat cushion assembly.

        Refer to PROCEDURE - Step 3

      2. Remove the rear seat cushion lock hook.

        Refer to PROCEDURE - Step 4

      3. Remove the rear floor service hole cover.
      4. Disconnect the fuel pump connector.
        GTY458485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Start the engine. After the engine has stopped on its own, turn the engine switch off.
        NOTE:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

      6. Crank the engine again and make sure that the engine does not start.

        HINT: 

        DTC P0171 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) or P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Refer to DTC CHECK / CLEAR [04/2013 - 08/2015]

      7. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      8. Disconnect the cable from the negative (-) battery terminal.
        NOTE:

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

        Refer to INITIALIZATION [04/2013 - 06/2014] , or refer to INITIALIZATION [06/2014 - 08/2015]

      9. Connect the fuel pump connector.
      10. Install the rear floor service hole cover with new butyl tape.
      11. Install the rear seat cushion lock hook.

        Refer to PROCEDURE - Step 8

      12. Install the rear seat cushion assembly.

        Refer to PROCEDURE - Step 9

  3. FUEL LINE 
    1. When disconnecting a high-pressure fuel line, a large amount of fuel will spray. Perform the following procedure:
      1. Discharge fuel system pressure.
      2. Disconnect the fuel tube.
      3. Drain the fuel remaining inside the fuel pump tube into a container.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Perform the following procedure when disconnecting a fuel tube connector (quick type A):
      NOTE:

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the claw and remove the fuel pipe clamp.
        GTY464827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pipe Clamp
      2. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.
        GTY465738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Pinch
        Pull Off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      3. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        GTY470209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Nylon Tube
        *c Fuel Pipe
        *d O-ring
        *e Fuel Tube Connector
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
        • Do not forcibly bend, twist or turn nylon tube.
      4. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    3. Perform the following procedure when connecting a fuel tube connector (quick type A):
      NOTE:

      Check if there is any damage or foreign matter on the connecting part of the fuel pipe.

      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.
        GTY465229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Push
      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
        GTY452003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Pull
      3. Engage the claw and install the fuel pipe clamp.
      4. Inspect for fuel leaks.
    4. Perform the following procedure when disconnecting a fuel tube connector (quick type B):
      NOTE:

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        GTY452531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Pull Out
        Pull Off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        GTY427899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuel Pipe
        *b Retainer
        *c Nylon Tube
        *d Fuel Tube Connector
        *e O-ring
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
        • Do not forcibly bend, twist or turn nylon tube.
      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    5. Perform the following procedure when connecting a fuel tube connector (quick type B):
      NOTE:

      Check if there is any damage or foreign matter on the connecting part of the fuel pipe.

      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.
        GTY423699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push In
      2. Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.
    6. Perform the following procedure when disconnecting a fuel tube connector (quick type C):
      NOTE:

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        GTY461861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Pull Out
        Pull Off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        GTY459884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Tube Connector
        *c O-ring
        *d Fuel Pipe
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the fuel pipe.
        • Do not forcibly bend, twist or turn nylon tube.
      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    7. Perform the following procedure when connecting the fuel tube connector (quick type C):
      NOTE:

      Check if there is any damage or foreign matter on the connecting part of the fuel pipe.

      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.
        GTY460235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push In
      2. Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.
    8. Observe the following precautions when handling the nylon tube:
      NOTE:
      • Do not twist the fuel tube connector part of the nylon tube or fuel tube connector when connecting them.
      • Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.
      • Do not pinch or kink the nylon tubes to prevent fuel leaks.
      GTY432431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector
  4. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    NOTE:
    • Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.
      GTY457235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tube
    • When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.
  5. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.

      See step  1

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