Fuel System: Precaution

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.

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.
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: Identifying Plug Connection With Rubber Plug
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Observe these precautions when removing and installing the injectors:
  
  Fig 3: Identifying Correct And Incorrect Position Of O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Never reuse the O-ring.
  - When placing a new O-ring on the injector, do not damage it.
  - Coat a new O-ring 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.
  NOTE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe or cylinder head contacts the O-ring of the injector.
  
  Fig 4: Installing Injector To Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 5: Detaching Lock Claw By Lifting Up Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. for Fuel Pipe Clamp Type:
    
    Fig 6: Identifying Fuel Pipe Clamp From Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Remove the fuel pipe clamp from the fuel tube connector.
  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.
    
    Fig 7: Pinching Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
  6. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
    
    Fig 8: Covering Connector By Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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 9: Pushing Pipe Into Connector
    Courtesy 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 10: Pulling Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. for Fuel Pipe Clamp Type:
    Install the fuel pipe clamp to the connector.
    
    Fig 11: Identifying Fuel Pipe Clamp To Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. for Fuel Hose Connector Cover Type:
    
    Fig 12: Attaching Lock Claws To Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
  6. Check that there is no fuel leakage.
CHECK FOR FUEL LEAKS
1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system (see INSTALLATION ).