Fuel System: Precaution

PRECAUTION
1. Before working on the fuel system, disconnect the cable from 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 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 cable from the battery negative terminal.
2. Remove the engine relay block cover.
3. Remove the circuit opening relay.
4. Connect the cable to the battery negative terminal.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
5. Start the engine.
6. Turn the ignition switch to ON after the engine stops.
  HINT:
  
  DTC P0171 (system to lean) may be present.
7. Crank the engine again and check that the engine stops.
8. Remove the fuel tank cap and discharge the pressure in the fuel tank completely.
9. Install the circuit opening relay.
  
  Fig 1: Installing Circuit Opening Relay
  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 tank main tube (see REMOVAL ).
  3. Drain the fuel 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 2: Disconnecting Fuel Tank Main Tube With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Take the following precautions when installing the fuel injector.
  1. Do not reuse the O-ring.
  2. Do not damage a new O-ring when installing it into the fuel injector.
  3. Before installing a new O-ring, apply gasoline or spindle oil.
    NOTE: Do not use engine oil, gear oil or brake oil.
    
    Fig 3: Correct & Wrong View Of O-Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install the fuel injector into the fuel delivery pipe and cylinder head as shown in Fig 4.
    NOTE: Apply gasoline or spindle oil to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector.
    
    Fig 4: Installing Fuel Injector Into Fuel Delivery Pipe & Cylinder Head
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Take the following precautions when disconnecting the fuel tube connector (type A).
  HINT:
  
  The structure of the fuel tube connector is as shown in Fig 4.
  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 5: Checking Fuel Tube Connector & Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Pinch the retainer as shown in Fig 6, and pull the fuel tube connector out of the pipe.
    
    Fig 6: Pinching Retainer
    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 it.
    NOTE: Never use any tools.
  4. 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 7: Checking Sealing Surface Of Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 8: Covering Disconnected Fuel Tube Connector & Pipe With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 9: Pushing Fuel Tube Connector
    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 10: Pulling Fuel Tube Connector & Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002