Fuel System: Precaution

PRECAUTIONS
1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
2. Do not smoke or work near an open flame when handling the fuel system.
3. Keep gasoline away from rubber or leather parts.
DISCHARGE FUEL SYSTEM PRESSURE CAUTION:
CAUTION:
- Perform the following procedure 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 procedure. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.
1. Remove the rear seat cushion assembly (See REMOVAL ).
2. Remove the rear floor service hole cover.
3. Disconnect the connector from the fuel pump assembly.
4. Start the engine. After the engine stops naturally, turn the ignition switch off.
  NOTE: Do not increase engine speed or drive the vehicle while waiting for the engine to stop naturally.
  
  Fig 1: Locating Rear Floor Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  DTC P0171/25 (system too lean) may be set.
5. Crank the engine again and make sure that the engine does not start.
6. Remove the fuel tank cap and discharge the pressure from the fuel tank.
7. Disconnect the cable from the negative (-) battery terminal.
8. Connect the connector of the fuel pump assembly.
9. Install the rear floor service hole cover.
10. Install the rear seat cushion assembly . See INSTALLATION .
  
  Fig 2: Locating Rear Floor Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FUEL LINE
1. When disconnecting a high-pressure fuel line, a large amount of gasoline will spray out. Perform the following procedure:
  1. Discharge fuel system pressure.
  2. Disconnect the fuel tube.
  3. Drain the fuel remaining inside the fuel pump tube into a container.
  4. Cover the disconnected pipe and connector with a plastic bag to prevent to damage and contamination.
  Fig 3: Identifying Connector With Plastic Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 4: Identifying Fuel Tube Connector Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Perform the following procedure when disconnecting a fuel delivery pipe (metallic type):
  HINT:
  
  The structure of a fuel tube connector is as shown in the illustration.
  1. Check if there is any damage or foreign objects on the pipe connections.
  2. Remove the No. 2 fuel pipe clamp.
    NOTE: Do not reuse the fuel pipe clamp.
  3. Find the metallic connector of the fuel tube assembly.
    
    Fig 5: Identifying No. 2 Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Assemble SST to the connector as shown in the illustration.
    SST 09268-21010
    
    Fig 6: Connecting SST To Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Turn SST, align the retainers inside the connector with the SST chamfers and insert SST into the connector.
  6. Slide SST and the connector together towards the fuel tube assembly.
3. Perform the following procedure when connecting a fuel tube connector (metallic type):
  1. Check if there is any damage or foreign objects on the pipe connections.
    
    Fig 7: Inserting SST Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Match the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe.
  3. After connecting, check if the pipe and the connector are securely connected by pulling on them.
    
    Fig 8: Pushing Pipe Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install a new No. 2 fuel pipe clamp.
  5. Check for fuel leaks.
    
    Fig 9: Identifying No. 2 Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Perform the following procedure when disconnecting a fuel tube connector (quick type A):
  1. Release the claw and remove the No. 1 fuel pipe clamp.
    
    Fig 10: Identifying No. 1 Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Disengage the lock claws by raising the fuel hose connector cover as shown in the illustration.
  3. Check that there is no dirt or other foreign objects on the pipe and contact surface before disconnecting them. Clean them if necessary.
  4. Disconnect the connector from the pipe by hand.
    
    Fig 11: Raising Fuel Hose Connector Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. If the connector and the pipe are stuck, push in and pull on the connector to release them. Pull the connector out of the pipe carefully.
  6. Check that there is no dirt or other foreign objects on the contact surface of the disconnected pipe. Clean them away if necessary.
    
    Fig 12: Pulling Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Cover the disconnected pipe and connector with a plastic bag to prevent to damage and contamination.
    
    Fig 13: Identifying Connector With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Perform the following procedure when connecting a fuel tube connectors (quick type A):
  1. Check if there is any damage or foreign objects on the pipe connections.
  2. Line up the two parts of the pipes to be connected, and push them together until the connector makes a "click" sound. 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.
  3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
    
    Fig 14: Connecting Fuel Tube Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Engage the lock claws to the connector by pushing down on the fuel hose connector cover.
    
    Fig 15: Pushing Down On Fuel Hose Connector Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Engage the lock claws and install the No. 1 fuel pipe clamp.
  6. Check for fuel leaks.
6. Perform the following procedure when disconnecting a fuel tube connector (Quick Type B):
  1. Before disconnecting the connector, clean off any dirt that may be present.
    
    Fig 16: Identifying No. 1 Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Pinch the tabs of the fuel tube retainer to disengage the 2 claws. Push the retainer down as shown in the illustration
    HINT:
    
    Be sure to disconnect the connector by hand.
    
    Fig 17: Pinching Tabs Of Fuel Tube Retainer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 are any dirt or any other foreign objects on the sealing surfaces of the disconnected pipes, clean them if necessary.
    
    Fig 18: Separating Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Cover the disconnected pipe and connector with a plastic bag to prevent to damage and contamination.
  Fig 19: Identifying Connector With Plastic Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Perform the following procedure when connecting a fuel tube connector (quick type B):
  1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat, then push the retainer in until the claws lock.
    
    Fig 20: 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 on them.
  3. Check for fuel leaks.
8. Perform the following procedure when disconnecting a fuel tube connector (quick type C):
  1. Check the pipe and around the connector for dirt and mud before disconnecting them. Clean them if necessary.
  2. Remove the checker of the fuel tube connector from the pipe.
  3. Pinch the tabs of the retainer of the fuel tube connector to disengage the lock claws and slide it as shown in the illustration.
  4. Check the sealing surface of the disconnected pipe for dirt and mud. Clean them away if necessary.
  5. Cover the disconnected fuel tube connector and pipe with a plastic bag to prevent damage and contamination.
  Fig 22: Disconnecting Fuel Tube Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Perform the following procedure when connecting a fuel tube connector (quick type C):
  1. Check the connected part of the pipe for any damage and foreign objects.
  2. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of clean engine oil to the tip of the pipe.
  3. Install a checker onto the pipe.
  4. Check for fuel leaks.
  Fig 23: Connecting Fuel Tube Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Observe the following precautions when handling a nylon tube:
  - Do not twist the connection part of the nylon tube and the quick connector when connecting them.
  - Do not bend, kink, or twist the nylon tube.
  - Do not remove the EPDM protector on the outside of the nylon tube.
  - Do not close the piping by kinking the nylon tube.
INJECTOR
1. Observe the following precautions when removing and installing a fuel injector:
  1. Do not reuse a O-ring and insulator.
  2. When placing a new O-ring onto the injector, do not damage the O-ring.
  3. Coat a new O-ring with grease or gasoline before installing it. Do not use engine oil, gear oil or brake fluid.
  Fig 24: Identifying O-Ring And Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the injector into the delivery pipe and cylinder head as shown in the illustration. Apply grease or gasoline to the contact surfaces of the injector before installing the injector.
Fig 25: Identifying Injector Into Delivery Pipe And Cylinder Head
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 suction tube assembly with pump and gauge. Doing so will cause reassembly of the fuel suction tube assembly with pump and gauge to be impossible as the tube is welded to the plate.
INSPECT FOR FUEL LEAK
1. Check that there are no fuel leakage after performing maintenance anywhere on the fuel system (See ON-VEHICLE INSPECTION ).
  
  Fig 26: Identifying Fuel Suction Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002