Fuel - Fuel System (2AZ-FE): Precaution

NOTE: When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.

SYSTEM SPECIFICATIONS

System	Refer To
Power window control system	INITIALIZATION
Sliding roof system	INITIALIZATION

PRECAUTION
1. Before working on the fuel system, disconnect the battery negative 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 SYSTEM 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 battery negative terminal.
2. Remove the rear seat cushion (See OVERHAUL ).
3. Remove the butyl tape, then remove the rear service hole cover.
4. Disconnect the fuel pump connector.
5. Connect the battery negative terminal.
  1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
6. Start the engine.
7. Turn the ignition switch to OFF after the engine stops.
  HINT:
  
  DTC P0171 (system to lean) may be present.
8. Crank the engine again, then check that the engine does not start.
9. Remove the fuel tank cap, then discharge the pressure in the fuel tank completely.
10. Disconnect the battery negative terminal.
  
  Fig 1: Disconnecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Connect the fuel pump connector.
12. Attach new butyl tape to the rear service hole cover.
13. Install the rear service hole cover, making sure it is aligned with the 2 convex of the floor panel.
14. Install the rear seat cushion (See OVERHAUL ).
15. Connect the battery negative terminal.
  1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  Fig 2: Connecting Fuel Pump Connector
  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 pump tube
    (See Removal & Installation and Disassembly & Reassembly ).
  3. Drain the pressure 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 3: Covering Disconnected Fuel Tank Main Tube With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Do not reuse the O-ring.
  6. Do not damage a new O-ring when installing it into the fuel injector.
  7. Before installing a new O-ring, apply gasoline or spindle oil.
    NOTE: Do not use engine oil, gear oil or brake oil.
    
    Fig 4: Installing New O-Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install the fuel injector into the fuel delivery pipe and cylinder head as illustrated in Fig 5.
    NOTE: Apply gasoline or spindle oil to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector.
    
    Fig 5: Installing Fuel Injector Into Fuel Delivery Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Take the following precautions when removing the fuel tube connector (metallic type).
  HINT:
  
  The structure of the fuel tube connector is as shown in Fig 6 .
  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 6: Checking Fuel Tube Connector And Pipe For Dirt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Hold the fuel tube connector in your hand, then install SST.
    1. SST 09268-21010
    NOTE: Perform this work with SST. Do not use any other tools.
    
    Fig 7: Installing SST In Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST. Insert SST into the fuel tube connector.
  4. Hold SST in the position above, then push the fuel tube connector towards the SST side. Mount the retainer of the fuel tube connector onto the chamfered part of SST.
    
    Fig 8: Identifying Retainer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    The retainer of the fuel tube connector is unlocked.
  5. Slide SST and the fuel tube connector together towards the fuel tube until they make a "click" sound, then disconnect the fuel tube.
  6. After removing the fuel tube, check the sealing surface of the pipe for dirt and mud.
    If dirty, wipe it with a shop rag.
  7. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 9: Covering Disconnected Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Take the following precautions when installing the fuel tube connector (metallic type).
  1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound.
    
    Fig 10: Aligning Fuel Tube Connector With 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 11: Connecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Take the following precautions when removing the fuel tube connector (type A).
  HINT:
  
  The structure of the fuel tube connector is as shown in Fig 12 .
  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 12: Checking Fuel Tube Connector And Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Pinch the retainer as illustrated in Fig 13, then pull the fuel tube connector out of the pipe.
    
    Fig 13: Pulling Fuel Tube Connector Out Of Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If the fuel tube connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector.
    NOTE: Never use any tools.
  4. After removing the fuel tube, check the sealing surface of the pipe for dirt and mud.
    
    Fig 14: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If dirty, wipe it with a shop rag.
  5. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 15: Covering Disconnected Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Take the following precautions when installing the fuel tube connector (type A).
  1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound.
    
    Fig 16: Aligning Fuel Tube Connector With 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 17: Connecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Take the following precautions when removing the fuel tube connector (type B).
  HINT:
  
  The structure of the fuel tube connector is as shown in Fig 18 .
  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 18: Checking Fuel Tube Connector And Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and push it down as shown in Fig 19 .
  3. Pull the fuel tank main tube out of the pipe.
    
    Fig 19: Removing Lock Claws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. If the fuel tube connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector.
    NOTE: Never use any tools.
  5. After removing the fuel tube, check the sealing surface of the pipe for dirt and mud.
    If dirty, wipe it with a shop rag.
    
    Fig 20: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and intrusion of foreign objects.
    
    Fig 21: Covering Disconnected Fuel Tube Connector And Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Take the following precautions when installing the fuel tube connector (type B).
  1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until it comes into contact with the seat, then push the retainer up until the claws lock.
    
    Fig 22: Aligning Fuel Tube Connector With 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 23: Connecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR FUEL LEAKS
1. Check that there are no fuel leaks after doing maintenance on the fuel system (See FUEL - FUEL SYSTEM (2AZ-FE) ).