Fuel System (2AZ-FE): Precaution

PRECAUTION
1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.
2. Do not smoke or be near an open flame when working on the fuel system.
3. Keep gasoline away from rubber or leather parts.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
- Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.
1. Remove the C/OPN relay from the engine room J/B.
2. Start the engine. After the engine has stopped, turn the ignition switch OFF.
  HINT:
  
  In some cases, DTC P0171 (system to lean) is output.
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 the negative (-) terminal cable from the battery.
6. Reinstall the C/OPN relay.
Fig 1: Removing C/OPN Relay From Engine Room J/B
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures.
  1. Try to prevent gasoline from spilling out.
  2. Disconnect the fuel pump tube (see REPLACEMENT ).
  3. Drain the fuel remaining inside the fuel pump tube.
  4. To protect the disconnected fuel pump tube from damage and contamination, cover it with a vinyl bag.
  5. Put a container under the connection.
  Fig 2: Covering Fuel Pump Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Observe these precautions when removing and installing the injector.
  1. Never reuse the O-rings.
  2. When placing a new O-ring on the injector, take care not to damage it in any way.
  3. Coat new O-rings with grease or gasoline before installing. Never use engine, gear or brake oil.
  Fig 3: Identifying Fuel Injector O-Ring Installation Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe touches the O-ring of the injector.
  
  Fig 4: Installing Injector To Delivery Pipe And Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe these precautions when disconnecting the fuel delivery pipe (metric type):
  HINT:
  
  The structure of the metallic connector is shown as left.
  1. Remove the fuel pipe clamp No. 2.
    
    Fig 5: Quick Connect Fitting
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Find the metallic connector of the fuel tube assembly, pull vehicle's and hold it as it is.
  3. Assemble SST to the connection as shown. SST 09268-21010
    
    Fig 6: Installing Release Tool
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector.
  5. Slide SST and the connector together towards the fuel tube assembly.
  Fig 7: Aligning Retainers Inside Connector With SST Chamfered Parts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Observe these precautions when connecting the fuel tube connector (metallic type).
  1. Check if 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 a "click" sound is heard. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.
    
    Fig 8: Connecting Tube Connector (Metallic Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.
  4. Check if there is any fuel leakage.
  Fig 9: Checking For A Good Connection
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Observe these precautions when disconnecting the fuel tube connector (quick type).
  1. Remove the fuel pipe clamp No. 1 from tube connector.
  2. Check for dirt or mud on the pipe and around the connector before the disconnection. Clean if necessary.
    
    Fig 10: Removing Fuel Pipe Clamp No. 1 From Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the connector from the hose while pinching part A with fingers, as shown in the illustration.
    
    Fig 11: Disconnecting Connector From Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. If the connector and the pipe are stuck, pinch the fuel pipe, push and pull the connector to disconnect the pipe and pull it out. Do not use any tools.
  5. Inspect for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
    
    Fig 12: Disconnecting And Removing Fuel Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. To protect the disconnected pipe and connector from damage and contamination, cover it with a vinyl bag.
  Fig 13: Covering Pipe And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Observe these precautions when connecting the fuel tube connector (quick type).
  1. Check that there is no damage or contamination in the connected part of the pipe.
  2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe.
    
    Fig 14: Connecting Fuel Tube Connector (Quick Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.
  4. Install the fuel pipe clamp to the connector.
  5. Check if there is any fuel leakage.
  Fig 15: Inspecting Fuel Tube Connector Proper Connection (Quick Type)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR FUEL LEAKS
1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see ON-VEHICLE INSPECTION ).