Fuel System: Precaution

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 lines even after performing the following procedures. When disconnecting a fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out.
1. For work associated with removal of the C/OPN relay:
  1. Separate the brake master cylinder reservoir assembly (See INTEGRATION RELAY ).
  2. Remove the reservoir bracket (See INTEGRATION RELAY ).
  3. Remove the No. 1 relay block cover (See REMOVAL ).
  4. Remove the C/OPN relay.
  5. Start the engine.
  6. After the engine stops, turn the ignition switch off.
    HINT:
    
    DTC P0171/25 (fuel problem) may be detected.
    
    Fig 1: Identifying C/OPN Relay
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Crank the engine again. Check that the engine does not start.
  8. Remove the fuel tank cap to discharge pressure from the fuel tank.
  9. Disconnect the cable from the negative (-) battery terminal.
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  10. Install the C/OPN relay.
  11. Install the No. 1 relay block cover (See INSTALLATION ).
  12. Install the reservoir bracket (See INSTALLATION ).
  13. Install the brake master cylinder reservoir assembly (See INSTALLATION ).
2. Perform the following to disconnect the fuel pump connector:
  1. Remove the rear No. 1 seat assembly (for LH side) (See REMOVAL ).
  2. Remove the rear No. 1 seat assembly (for RH side) (See REMOVAL ).
  3. Using a clip remover, remove the 3 clips and lift up the front floor carpet, (w/rear No. 2 seat)
    
    Fig 2: Locating Front Floor Carpet Clips
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Disengage the 3 claws and lift up the front floor carpet, (w/o rear No. 2 seat)
    
    Fig 3: Identifying Front Floor Carpet Claws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove the rear floor service hole cover.
  6. Disconnect the fuel pump connector.
  7. Start the engine.
  8. After the engine stops, turn the ignition switch off.
    HINT:
    
    DTC P0171/25 (fuel problem) may be detected.
    
    Fig 4: Locating Fuel Pump Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Crank the engine again. Check that the engine does not start.
  10. (10)Remove the fuel tank cap to discharge pressure from the fuel tank.
  11. Disconnect the cable from the negative (-) battery terminal.
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  12. Reconnect the fuel pump connector.
  13. Install the rear floor service hole cover.
    
    Fig 5: Locating Fuel Pump Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Install the front floor carpet and the 3 clips, (w/rear No. 2 seat)
    
    Fig 6: Locating Front Floor Carpet Clips
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Engage the 3 claws to install the front floor carpet, (w/o rear No. 2 seat)
  16. Install the rear No. 1 seat assembly (for LH side) (See INSTALLATION ).
  17. Install the rear No. 1 seat assembly (for RH side) (See INSTALLATION ).
  Fig 7: Identifying Front Floor Carpet Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PRECAUTIONS
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.
FUEL LINE
1. When disconnecting a high pressure fuel line, a large amount of gasoline will spill out, so perform the following procedures:
  1. Discharge fuel system pressure.
  2. Disconnect the fuel pump tube (See REMOVAL ).
  3. Drain the fuel that remains in the fuel pump tube.
  4. Cover the disconnected fuel pump tube with a plastic bag to prevent damage and contamination.
  5. Put a container under the connectors.
  Fig 8: Covering Fuel Pump Main Tube From Plastic Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Perform the following procedure when disconnecting the fuel tube.
  NOTE: Do not forcibly bend, kink or twist the fuel tube.
  1. Remove the fuel tube from the fuel hose clamp.
  2. Remove the No. 2 fuel pipe clamp.
  3. Wipe off any dirt on the fuel tube connector.
  4. Hold the fuel tube connector, and then install SST.
    SST 09268-21010
  5. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.
  6. Insert SST into the fuel tube and hold it. Then push the fuel tube connector toward SST.
  7. Mount the retainer of the fuel tube connector onto the chamfered part of SST.
    
    Fig 9: Disconnecting Fuel Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Slide SST and the fuel tube connector together toward the fuel tube until they make a "click" sound, and then disconnect the fuel tube.
  9. Drain the fuel remaining inside the fuel tube.
  10. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected part.
  Fig 10: Identifying O-Ring, Retainer, Nylon Tube, Pipe And Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Perform the following procedure when connecting the fuel tube connector.
  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 11: Identifying No. 2 Fuel Pipe Clamp And Fuel Hose Clamp
    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. Inspect for fuel leaks.
  5. Install a new No. 2 fuel pipe clamp.
  6. Install the fuel tube to the fuel hose clamp.
  Fig 12: Connecting Quick Connector To Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Perform these procedure when disconnecting the fuel tube connector (Quick Type A):
  1. Remove the No. 1 fuel pipe clamp.
  2. Check whether there is any dirt in the pipe around the connector before disconnecting it and remove the dirt as necessary.
    
    Fig 13: Identifying No. 1 Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the connector from the pipe by hand.
    NOTE: Be sure to disconnect the connector by hand.
  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.
    
    Fig 14: Disconnecting Connector From Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Be sure to disconnect the connector by hand.
  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. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
  Fig 15: Covering Pipe And Connector With Plastic Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Perform the following procedure when connecting a fuel tube connector (Quick Type A):
  1. Check if there is any damage or foreign objects on the connecting parts of the pipes.
  2. Line up the 2 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. Inspect for fuel leaks.
  5. Install the No. 1 fuel pipe clamp.
  Fig 16: Connecting Fuel Tube Connector (Quick Type A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Perform the following procedure 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.
    
    Fig 17: Detaching Claws Of Connector Retainer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Be sure to disconnect the connector by hand.
  3. If the connector and pipe are stuck, push and pull on the connector while holding the pipe by hand. Pull the 2 pipes apart to separate the connector.
    NOTE: Be sure to disconnect the connector by hand.
    
    Fig 18: Disconnecting Quick Type B Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check if there is any dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the sealing surfaces if necessary.
  5. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
  Fig 19: Covering Connector And Pipe With Plastic Bag (Quick Type B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Perform the following procedure when connecting a fuel tube connector (Quick Type B):
  1. Line up the 2 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.
    
    Fig 20: Connecting Fuel Tube Connector (Quick Type B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
  3. Inspect for fuel leaks.
8. 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.
INJECTOR
1. Install the injector to the delivery pipe and the lower intake manifold as shown in the illustration.
  NOTE: Before installing the injector, be sure to apply a light coat of gasoline or spindle oil where the delivery pipe contacts the injector O-ring.
  
  Fig 21: Identifying Fuel Delivery Pipe, Fuel Injector, O-Ring And Insulator
  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 spindle oil or gasoline before installing it.
    NOTE: Do not use engine oil, gear oil or brake fluid.
    
    Fig 22: Precautions For Removing And Installing Of Fuel Injectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
1. Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube assembly with pump and gauge. Doing so will cause reassembly of the fuel suction tube assembly with pump and gauge to be impossible as the tube is welded to the plate.
Fig 23: Identifying Fuel Suction Tube Assembly With Pump And Gauge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 ).