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Fuel System: Precaution: Precaution

  1. PRECAUTION 
    1. Before starting work on the fuel system, including inspections and repairs, disconnect the cable from the negative (-) battery terminal.
    2. Do not smoke or work near fire when performing work on the fuel system.
    3. Keep gasoline away from rubber or leather parts.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • Take precautions to prevent gasoline from spilling out before removing fuel system parts.
    • Pressure still remains in the fuel lines even after performing the following procedures. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.
    1. Remove the circuit opening relay from the engine room relay block.
    2. Start the engine. After the engine stops, turn the ignition switch off.

      HINT: 

      DTC P0171 (system to lean) may be stored.

    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 cable from the negative (-) battery terminal.
    6. Reinstall the circuit opening relay.
  3. FUEL SYSTEM 
    1. When disconnecting a high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures.
      1. Disconnect the fuel pump tube.
      2. Drain any fuel remaining inside the fuel pump tube.
      3. To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag.
      4. Put a container under the connection.
    2. Observe these precautions when removing and installing the injectors.
      Fig 1: Identifying Injector, Delivery Pipe & Lower Intake Manifold
      GTY216120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Never reuse the O-ring.
      2. When installing a new O-ring to the injector, do not damage it.
      3. Coat new O-rings with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake oil.
    3. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
      Fig 2: Identifying Injector, Delivery Pipe, Lower Intake Manifold & O-Ring
      GTY234034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-Ring
      NOTE:

      Before installing the injector, be sure to apply spindle oil or gasoline to the place where the delivery pipe or cylinder head contacts the O-ring of the injector.

    4. Observe these precautions when disconnecting the fuel tube connector (for quick type A).
      Fig 3: Identifying Fuel Tube Connector (For Quick Type A)
      GTY284085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Fuel hose connector cover type:

        Detach the lock claw by lifting up the cover as shown in the illustration.

        TEXT IN ILLUSTRATION

        *1 Fuel Hose Connector Cover
      2. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
      3. If the connector and the pipe are stuck, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out.
        Fig 4: Pinching Fuel Pipe Connector
        GTY278055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        Pinch
        Pull
        NOTE:
        • Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
          Fig 5: Identifying Fuel Tube Connector Components
          GTY271521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Do not use any tools to separate the pipe and connector.
        • Do not forcefully bend or twist the nylon tube.
        • Check for foreign matter on the pipe seal surface. Clean if necessary.
        • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
        • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
        TEXT IN ILLUSTRATION

        *1 Retainer
        *2 Nylon Tube
        *3 Pipe
        *4 O-Ring
        *5 Fuel Tube Connector
      4. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
      5. To protect the disconnected pipe and connector from damage and contamination, cover them with a plastic bag.
    5. Observe these precautions when connecting the fuel tube connector (for quick type A).
      Fig 6: Pushing Connector Onto Pipe
      GTY269690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 a small amount of fresh engine oil to the tip of the pipe.
        TEXT IN ILLUSTRATION

        Push
      3. After connecting the pipe and the connector, check that the pipe is securely connected by trying to pull them apart.
        Fig 7: Checking For Secure Connection
        GTY269691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
      4. Fuel hose connector cover type:

        Attach the lock claws to the connector by pushing down on the cover.

      5. Check for any fuel leaks.
    6. Observe these precautions when disconnecting the fuel tube connector (for quick type B):
      1. Check if there is any dirt or mud on the pipe and around the connector before disconnecting them. Clean if necessary.
      2. Disconnect the parts by hand.
        3. Fig 8: Disconnecting Fuel Tube Connector
        GTY182476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
          Fig 9: Identifying O-Ring, Retainer, Pipe & Nylon Tube
          GTY233513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Do not use any tools to separate the pipe and connector.
        • Do not forcefully bend or twist the nylon tube.
        • Check for foreign matter on the pipe seal surface. Clean if necessary.
        • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
        • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
      3. If the connector and pipe are stuck, push and pull the connector to disconnect the pipe and pull it out.
        TEXT IN ILLUSTRATION

        Turn
        Pull
        TEXT IN ILLUSTRATION

        *1 Nylon Tube
        *2 O-Ring
        *3 Retainer
        *4 Pipe
      4. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
      5. To protect the disconnected pipe and connector from damage and contamination, cover them with a plastic bag.
    7. Observe these precautions when connecting the fuel tube connector (for quick type B):
      1. Align the axis of the connector with the axis of the pipe, and push in the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of new engine oil to the tip of the pipe.
        Fig 10: Connecting Fuel Tube Connector
        GTY182475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Push
      2. After connecting the pipe and the connector, check that the pipe is securely connected by trying to pull them apart.
        Fig 11: Checking Connection Of Pipe & Connector
        GTY182486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
      3. Check for fuel leaks.
    8. Observe these precautions when disconnecting the fuel tube connector (for quick type C).
      1. Check that there is no damage or foreign matter on the part of the pipe that contacts the connector.
      2. Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe.
        Fig 12: Disconnecting Connector From Pipe
        GTY189988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        Push
        Down
        Pull

        HINT: 

        If the connector and pipe are stuck, pinch the fuel pipe by hand, and push and pull the connector to disconnect it.

        Fig 13: Disconnecting Connector
        GTY104528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
        Push
        NOTE:
        • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
          Fig 14: Identifying Pipe Connector Components
          GTY262514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Do not use any tools to separate the pipe and connector.
        • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
        • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
        • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
        TEXT IN ILLUSTRATION

        *1 Pipe
        *2 Retainer
        *3 Nylon Tube
        *4 Connector
        *5 O-Ring
      3. Check for foreign matter on the seal surface of the disconnected pipe. Clean it if necessary.
      4. To protect the disconnected pipe and connector from damage and foreign matter, cover them with a plastic bag.
    9. Observe these precautions when connecting the fuel tube connector (for quick type C).
      1. Check for foreign matter on the pipe and around the connector before connecting it. Clean it if necessary.
      2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector, and then push up on the retainer.
        Fig 15: Pushing Connector Onto Pipe
        GTY263244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        Up
        Push
        NOTE:
        • Before connecting the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
        • After connecting the pipe and the connector, check that the pipe is securely connected by trying to pull them apart.
          Fig 16: Checking For Secure Connection
          GTY257980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
    10. Observe these precautions when handling the nylon tube.
      NOTE:
      • Be careful not to turn the connection part of the nylon tube and the quick connector when connecting them.
      • Do not kink the nylon tube.
      • Do not remove the EPDM protector on the outside of the nylon tube.
      • Do not bend the nylon tube as this may cause blockage.
    11. Observe these precautions when disconnecting the fuel tank breather tube connector:
      Fig 17: Pinching & Pulling Out Fuel Tank Breather Tube Connector
      GTY278492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Fuel Tank Breather Tube Connector
      *2 Pipe
      Push
      Pinch
      1. Pinch the retainer and pull out the fuel tank breather tube connector with the fuel tank breather tube connector pushed toward the pipe to disconnect the fuel tank breather tube from the pipe.
        NOTE:
        • Remove dirt or foreign objects on the fuel tank breather tube connector before performing this procedure.
          Fig 18: Identifying Cross Section Of Fuel Tank Breather Tube Connector
          GTY276007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank breather tube connector has the O-ring that seals the pipe.
        • Perform this work by hand. Do not use any tools.
        • Do not forcibly bend, kink or twist the nylon tube.
        • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank breather tube.
        • If the fuel tank breather tube connector and pipe are stuck, push and pull them to release them.
        TEXT IN ILLUSTRATION

        *1 Fuel Tank Breather Tube Connector
        *2 Pipe
        *3 Nylon Tube
        *4 O-Ring
    12. Observe these precautions when connecting the fuel tank breather tube connector:
      Fig 19: Identifying Fuel Tank Breather Tube Connector
      GTY182017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Align the fuel tank breather tube connector with the pipe, and then push in the fuel tank breather tube connector until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
        TEXT IN ILLUSTRATION

        Push
        NOTE:
        • Check that there are no scratches or foreign objects on the connected part of the fuel tank breather tube connector and pipe before performing this procedure.
        • After connecting the fuel tank breather tube, check that the fuel tank breather tube is securely connected by pulling the fuel tank breather tube connector.
      2. After connecting the pipe and the connector, check that the pipe is securely connected by trying to pull them apart.
        Fig 20: Identifying Fuel Tank Breather Tube Connector
        GTY182018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
      3. Inspect for fuel leaks.
    13. Observe these precautions when disconnecting the fuel cut-off tube connector:
      1. Pinch the projection of the retainer to detach the lock claws and pull out the fuel cut-off tube.
        Fig 21: Detaching Lock Claws & Pulling Out Fuel Cut-Off Tube
        GTY226979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Fuel Tank Breather Tube Connector
        *2 Pipe
        Push
        Pinch
        NOTE:
        • Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
          Fig 22: Identifying O-Ring, Retainer, Pipe & Nylon Tube
          GTY218900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-ring may not properly seal the connection.
        • Disconnect the quick connector by hand.
        • Do not bend or twist the nylon tube.
        • To protect the tubes, cover them with a plastic bag after checking for dirt.
        • If the connector and the pipe are stuck, try wiggling or pushing and pulling the connector to release it. Pull the connector off of the pipe carefully.
        TEXT IN ILLUSTRATION

        *1 Nylon Tube
        *2 O-Ring
        *3 Retainer
        *4 Pipe
    14. Observe these precautions when connecting the fuel tank breather tube connector:
      1. Push in the tube connector to the pipe until the connector makes a "click" sound.
        Fig 23: Pushing Tube Connector Into Pipe
        GTY226978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Push
        NOTE:
        • Check if there is any damage or foreign objects on the connected part of the pipe.
        • After connecting the pipe and the connector, check that the pipe is securely connected by trying to pull them apart.
          Fig 24: Checking Connection Of Pipe & Connector
          GTY235697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
      2. Inspect for fuel leaks.
  4. INSPECT FOR FUEL LEAK 
    1. Inspect for fuel leaks. Refer to INSTALLATION - Step 7 .
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