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Fuel System: Precaution

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
  • Do not smoke or be near an open flame when working on the fuel system.
  • Keep gasoline away from rubber or leather parts.
  1. 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 cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
    1. Disconnect the cable from the negative (-) battery terminal.
      NOTE:
      • Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
      • After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
    2. Disconnect the 2 fuel pump ECU connectors.
    3. Connect the cable to the negative (-) battery terminal.
    4. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.

      HINT:

      DTC P0171/0174 (system too lean) may be set.

    5. Crank the engine again, then check that the engine does not start.
    6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
    7. Connect the 2 fuel pump ECU connectors.
      Fig 1: Locating Fuel Pump ECU Connectors
      G05152110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. FUEL SYSTEM 
    1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures.
      1. Discharge the fuel system pressure (see above procedure).
      2. Put a container under the connecting part of the pressure line.
      3. Slowly loosen the connection.
      4. Disconnect the connection.
      5. Plug the connection with a rubber plug.
        Fig 2: Plugging Connection With Rubber Plug
        G05151871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe the following procedures.
      NOTE: Make sure to install the gaskets in the order shown in the illustration, as the shape of the upper side and lower side gaskets is different.
      1. Always use 2 new gaskets.
      2. Tighten the union bolt by hand.
        Fig 3: Connecting Union Bolt (Fuel Pressure Pulsation Damper) On High Pressure Pipe Union
        G05152112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using SST, tighten the union bolt to the specified torque.

        SST 09612-24014(09617-24011) 

        Torque: 

        with SST 

        33 N*m (340 kgf*cm, 24 ft.*lbf) 

        without SST 

        39 N*m (398 kgf*cm, 29 ft.*lbf) 

        HINT:

        • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.).
        • Make sure SST and wrench are connected in a straight line.
          Fig 4: Tightening Union Bolt Using SST
          G05152113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Observe the following precautions when removing or installing the injectors:
      • Never reuse the O-ring.
      • When placing a new O-ring on the injector, do not damage the O-ring.
      • Coat a new O-ring with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake fluid.
        Fig 5: Precautions For Removing Or Installing Injectors
        G05152114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the injector to the delivery pipe and intake manifold, as shown in the illustration.
      NOTE: Before installing the injector, apply spindle oil or gasoline where the delivery pipe or intake manifold contacts the O-ring of the injector.
      Fig 6: Installing Injector To Delivery Pipe And Intake Manifold
      G05152115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Observe these precautions when disconnecting the fuel tube connector (for quick type).
      1. for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration.
        Fig 7: Identifying Fuel Tube Connector For Fuel Hose Connector Cover Type
        G05151874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector.
        Fig 8: Identifying Fuel Tube Connector For Fuel Pipe Clamp Type
        G05152117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
      4. Pinch the connector and disconnect the connector and pipe.

        If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out.

        NOTE: Do not use any tools.
      5. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
        Fig 9: Pinching Connector And Disconnect Connector And Pipe
        G05151876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
        Fig 10: Covering Disconnected Pipe And Connector With Plastic Bag
        G05151877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Observe these precautions when connecting the fuel tube connector (for 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 a small amount of fresh engine oil on the tip of the pipe.
        Fig 11: Pushing Pipe Into Connector Until Connector Makes Click Sound
        G05151878Courtesy 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.
        Fig 12: Pulling Apart Pipe And Connector
        G05151879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector.
        Fig 13: Identifying Fuel Pipe Clamp
        G05152117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. for Fuel Hose Connector Cover Type: Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
        Fig 14: Identifying Fuel Hose Connector Cover Type
        G05151881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Check that there is no fuel leakage.
  3. CHECK FOR FUEL LEAK 
    1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system (see INSTALLATION  ).
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