Fuel System: Precaution

PRECAUTION
1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
2. Do not smoke or work near fire when handling the fuel system.
3. Keep gasoline away from rubber or leather parts.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Perform the following procedures to prevent fuel from spilling out before removing any fuel system parts.
- Pressure will still remain in the fuel line even after performing the following procedures. When disconnecting the fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out.
1. Remove the rear seat cushion assembly.
2. Remove the rear floor service hole cover.
3. Connect the intelligent tester to the DLC3.
4. Set the vehicle to the "Inspection Mode" (See INSPECTION MODE PROCEDURE ).
5. Start the engine.
6. Disconnect the fuel pump connector.
  
  Fig 1: Locating Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. After the engine has stopped on its own, turn the power switch off.
  HINT:
  
  DTC P0171/25 (fuel problem) may be detected.
8. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
9. Disconnect the cable from the negative (-) battery terminal.
10. Reconnect the fuel pump connector.
11. Install the rear floor service hole cover.
12. Install the rear seat.
FUEL SYSTEM
1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe the following procedures:
  1. Discharge the fuel system pressure. (Step 2)
  2. Disconnect the fuel pump tube (See REMOVAL ).
  3. Drain the fuel that remains inside the fuel pump tube.
  4. To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag.
  5. Put a container under the connectors.
    
    Fig 2: Covering Fuel Pump Main Tube With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Observe the following precautions when removing and installing the fuel injectors:
  1. Never reuse an O-ring.
  2. When placing a new O-ring on the injector, do not damage the O-ring.
  3. Coat a new O-ring with gasoline before installing it.
    NOTE: Do not use engine oil, gear oil or brake fluid.
    
    Fig 3: Identifying Correct And Incorrect Position Of O-Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the injector to the delivery pipe and cylinder head, as shown in the illustration.
  NOTE: Before installing the injector, be sure to apply appropriate lubricant or gasoline to the place where the delivery pipe or cylinder head contacts the O-ring of the injector.
  
  Fig 4: Installing Injector To Delivery Pipe And Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe the following precautions when disconnecting the fuel delivery pipe (metallic type):
  HINT:
  
  The structure of the metallic connector is shown in Fig 5.
  
  Fig 5: Identifying Fuel Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Remove the No. 2 fuel pipe clamp.
    HINT:
    
    The No. 2 fuel pipe clamp cannot be reused.
    
    Fig 6: Locating No. 2 Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Find the metallic connector of the fuel tube assembly.
  3. Assemble SST to the connection as shown in the illustration.
    SST 09268-21010
    
    Fig 7: Assembling SST To Connection
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector.
  5. Slide the SST and the connector together towards the fuel tube assembly.
5. Observe the following precautions when connecting the fuel tube connector (metallic type):
  1. Check if there is any damage or foreign objects on the connecting 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. If the connection is tight, apply a small amount of clean engine oil to the tip of the pipe.
    
    Fig 8: Matching Axis Of Connector With Axis Of Pipe And Pushing Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After finishing the connection, check if the pipe and the connector are securely connected by pulling on them.
  4. Check for fuel leaks.
    
    Fig 9: Checking Pipe And Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Install a new No. 2 fuel pipe clamp.
    
    Fig 10: Locating No. 2 Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Observe the following precautions when disconnecting the fuel tube connectors (Quick type A):
  1. Remove the No. 1 fuel pipe clamp from the tube connector.
  2. Check that there is no dirt or other foreign objects on the pipe and around the connector before disconnecting them. Clean them if necessary.
    
    Fig 11: Identifying Fuel Pipe Clamp From Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the connector from the pipe by hand.
    
    Fig 12: Disconnecting Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. If the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.
  5. Check that there is no dirt or other foreign objects on the sealing surface of the disconnected pipe. Clean the surfaces if necessary.
  6. Do not damage the disconnected pipe and connector. Prevent entry of foreign objects by coverings the connectors with plastic bags.
    
    Fig 13: Covering Connectors With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Observe the following precautions when connecting the fuel tube connectors (Quick Type A):
  1. Check if there is any damage or foreign objects on the connecting parts of the pipes.
  2. Line up the two parts of the pipes to be connected, and push them together until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.
  3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
  4. Check for fuel leaks.
    
    Fig 14: Precaution Connecting Fuel Tube Connectors (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Observe the following precautions when disconnecting the fuel tube connector (Quick type B):
  1. Before disconnecting the connector, clean off any dirt that may be present.
  2. Pinch the tabs of the fuel tube retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.
    HINT:
    
    Be sure to disconnect the connector by hand.
    
    Fig 15: Precautions Disconnecting Fuel Tube Connector (Quick Type B) (1 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If the connector and pipe are stuck, hold the fuel pipe by hand and push and pull on the connector. Pull the two pipes apart to separate the connector.
  4. Check if there is any dirt or any other foreign objects on the sealing surfaces of the disconnected pipes. Clean the sealing surfaces if necessary.
    
    Fig 16: Precautions Disconnecting Fuel Tube Connector (Quick Type B) (2 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Do not damage the disconnected pipe and connector, and prevent entry of foreign objects by covering the connectors with plastic bags.
    
    Fig 17: Precautions Disconnecting Fuel Tube Connector (Quick Type B) (3 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Observe the following precautions when connecting the fuel tube connector (Quick Type B):
  1. Line up the two parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.
  2. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
  3. Check for fuel leaks.
    
    Fig 18: Precautions Connecting Fuel Tube Connector (Quick Type B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Observe the following precautions when handling a nylon tube:
  CAUTION:
  - Do not twist the connector part of the nylon tube or the quick connector when connecting them.
  - Do not bend or twist the nylon tube.
  - Do not remove the EPDM protector on the outside of the nylon tube.
  - Do not pinch or kink the nylon tubes to prevent fuel leakage.
INSPECT FOR FUEL LEAK
1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs (See ON-VEHICLE INSPECTION ).