Fuel System: Precaution

PRECAUTION
1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
2. Do not smoke or work near fire when handling the fuel system.
3. Keep gasoline away from rubber or leather parts.
DISCHARGE FUEL SYSTEM PRESSURE
NOTE:
- Perform the following procedures to prevent fuel from spilling out before removing any fuel system parts.
- Pressure will still remain in the fuel lines even after performing the following procedures. When disconnecting a fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out.
1. Connect the Techstream to the DLC3.
2. Put the vehicle in the "inspection mode" (See INSPECTION MODE PROCEDURE ).
3. Start the engine.
4. Turn the Techstream main switch on.
5. Select the following menu items: Power train / Engine and ECT / Active Test / Control the Fuel Pump Speed.
6. Turn the fuel pump off.
7. Turn the power switch off immediately after the engine comes to a "rough idle state".
NOTE: The hybrid system has a complicated process from "out of gas" to "engine stall". Therefore, "rough idle" is regarded as "stop".

HINT:

DTCs P0171/25 may be detected.
FUEL LINE
1. When disconnecting the fuel line, fuel will splash. So take the following precautions:
  1. Put a container under the connection.
  2. Disconnect the fuel tube.
  3. Drain the fuel remaining inside the fuel tank main tube into the container.
  4. Cover the disconnected fuel tank main tube (fuel tube joint and fuel tube connector) with a plastic bag to prevent damage and intrusion of foreign matter.
    
    Fig 1: Identifying Fuel Tank Main Tube With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Observe the following precautions when disconnecting the fuel tube connector (quick type A).
  1. For fuel pipe clamp type:
    Remove the No. 1 fuel pipe clamp.
    
    Fig 2: Locating Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. For fuel hose connector cover type:
    Pull up the fuel hose connector cover to release the lock, as shown in the illustration.
  3. Check for foreign matter on the pipe and around the connector before disconnecting it. Clean it if necessary.
    
    Fig 3: Identifying Fuel Hose Connector Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. If the connector and pipe are stuck, pinch the connector, and push and pull the pipe to disconnect them.
    NOTE: Do not use any tools in this procedure.
  5. Check for foreign matter on the seal surface on the disconnected pipe. Clean it if necessary.
    
    Fig 4: Disconnecting Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. To protect the disconnected pipe and connector from damage and foreign matter, cover it with a plastic bag.
3. Observe the following precautions when connecting the fuel tube connector (quick type A).
  1. Check that there is no damage or foreign matter on the part of the pipe that contacts the connector.
  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 too tight, apply a small amount of fresh engine oil to the tip of the pipe.
    
    Fig 6: Pushing Pipe Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After connecting the pipe and connector, try to pull them apart to confirm that they are securely connected.
    
    Fig 7: Pulling Pipe From Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. For fuel hose connector cover type: Attach the lock claws to the connector by pushing down on the cover.
    
    Fig 8: Locating Fuel Hose Connector Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. For fuel pipe clamp type: Install the No. 1 fuel pipe clamp.
  Fig 9: Locating No. 1 Fuel Pipe Clamp Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe the following precautions when disconnecting the fuel tube connector (quick type B).
  1. Before disconnecting the connector, clean off any dirt that may be present.
  2. Pinch the tabs of the fuel tube retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.
    
    Fig 10: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    Be sure to disconnect the connector by hand.
  3. If the connector and pipe are stuck, hold the fuel pipe by hand and push and pull on the connector. Pull the two pipes apart to separate the connector.
  4. If there is any dirt or any other foreign objects on the sealing surfaces of the disconnected pipes, clean them if necessary.
    
    Fig 11: Separating Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Do not damage the disconnected pipe and connector, and prevent entry of foreign objects by covering them with plastic bags.
  Fig 12: Identifying Disconnected Pipe And Connector With Plastic Bags
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Observe the following precautions when connecting the fuel tube connector (quick type B).
  1. Line up the two parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.
    
    Fig 13: Connecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
  3. Check for fuel leaks.
6. Observe the following precautions when handling a nylon tube:
CAUTION:
- Do not twist the connection part of the nylon tube or the quick connector when connecting them.
- Do not bend or twist the nylon tube.
- Do not remove the EPDM protector on the outside of the nylon tube.
- Do not close the piping by bending the nylon tube.
INJECTOR
1. Observe the following precautions when removing and installing fuel injectors:
  1. Do not reuse the O-ring.
  2. When placing a new O-ring onto the injector, do not damage the O-ring.
  3. Coat the new O-ring with grease or gasoline before installing it. Do not use engine oil, gear oil or brake fluid.
2. Install the injector into the delivery pipe and intake manifold, as shown in the illustration. Apply grease or gasoline oil to the contact surfaces of the delivery pipe and the injector before installing the injector.
  
  Fig 15: Identifying Injector Components
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
1. Do not disconnect the tube shown in the illustration when disassembling the fuel pressure regulator. Doing so will cause reassembly of the fuel pressure regulator to be impossible as the tube is welded to the pump.
  
  Fig 16: Locating Fuel Suction Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FOR FUEL LEAK
1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs (See FUEL SYSTEM ).