Fuel System (2TR-FE): Precaution

PRECAUTION
1. Before working on the fuel system, disconnect the cable from the negative battery terminal.
2. Do not work on the fuel system near fire. Never smoke during the work.
3. Keep rubber and leather parts away from gasoline.
DISCHARGE FUEL PRESSURE
CAUTION:
- Before removing fuel system parts, take precautions to prevent gasoline spillage.
- As some pressure remains in the fuel line even after taking precautions to prevent gasoline spillage, use a shop rag to prevent gasoline splashes when disconnecting the fuel line.
1. Disconnect the cable from the negative battery terminal.
2. Remove the engine relay block cover.
3. Remove the circuit opening relay.
4. Connect the cable to the negative battery terminal. Torque: 3.9 N.m (40 kgf.cm, 35 in..lbf)
5. Start the engine.
6. Turn the ignition switch to ON after the engine stops.
  HINT:
  
  DTC P0171 (system to lean) may be present.
7. Crank the engine again, and check that the engine stops
8. Remove the fuel tank cap, and discharge the pressure in the fuel tank completely
9. Install the circuit opening relay.
  
  Fig 1: Removing Circuit Opening Relay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FUEL SYSTEM
1. When disconnecting the high-pressure fuel line, a large amount of gasoline will splash. So take the following precautions.
  1. Discharge the fuel system pressure (step 2).
  2. Disconnect the fuel tank main tube (see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY ).
  3. Drain the fuel remaining in the fuel tank main tube.
  4. Cover the disconnected fuel tank main tube (fuel tube joint and fuel tube connector) with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 2: Covering Disconnected Fuel Tank Main Tube With A Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Take the following precautions when installing the fuel injector.
  1. Do not reuse the O-ring.
  2. Do not damage a new O-ring when installing it onto the fuel injector.
  3. Before installing a new O-ring, apply gasoline or spindle oil.
    
    Fig 3: Precautions For O-Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Do not use engine oil, gear oil or brake oil.
  4. Install the fuel injector into the fuel delivery pipe and cylinder head as illustrated.
  HINT:
  
  Apply gasoline or spindle oil to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector.
  
  Fig 4: Installing Fuel Injector Into Fuel Delivery Pipe And Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Take the following precautions when disconnecting the fuel tube connector.
  HINT:
  
  The structure of the fuel tube connector is as shown in the illustration.
  1. Check the fuel tube connector and pipe for dirt and mud before removing the fuel tube connector.
    If dirty, wipe it with a shop rag.
    
    Fig 5: Precautions For Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
    
    Fig 6: Pinching Retainer For Pulling Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If the fuel tube connector and pipe are stuck, pinch the pipe and push and pull the fuel tube connector to release it.
    NOTE: Never use any tools.
  4. After disconnecting the fuel tube, check the sealing surface of the pipe for dirt and mud.
    If dirty, wipe it with a shop rag.
    
    Fig 7: Pinching Pipe And Pulling Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 8: Covering Disconnected Fuel Tube Connector And Pipe With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Take the following precautions when installing the fuel tube connector.
  1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound.
    
    Fig 9: Pushing Fuel Tube Connector Into Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
    
    Fig 10: Checking Fuel Tube Connector And Pipe Are Securely Connected
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002