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Fuel System: Precaution

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    CAUTION:
    • 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. For work associated with removal of the FUEL PUMP relay:
      1. Remove the relay block cover.
      2. Remove the FUEL PUMP relay.
      3. Start the engine.
      4. After the engine stops, turn the ignition switch off.

        HINT:

        DTC P0171/25 (fuel problem) may be detected.

      5. Crank the engine again. Check that the engine does not start.
      6. Remove the fuel tank cap to discharge pressure from the fuel tank.
      7. Disconnect the cable from the negative (-) battery terminal.
        Fig 1: Identifying Fuel Pump Relay
        G05414756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      8. Install the FUEL PUMP relay.
    2. Perform the following to disconnect the fuel pump connector:
      1. Remove the rear No. 1 seat assembly (for LH side) (See REMOVAL ).
      2. Remove the rear No. 1 seat assembly (for RH side) (See REMOVAL ).
      3. Using a clip remover, remove the 3 clips and lift up the front floor carpet. (w/ rear No. 2 seat)
        Fig 2: Locating Clips And Front Floor Carpet
        G05414757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Disengage the 3 claws and lift up the front floor carpet. (w/o rear No. 2 seat)
        Fig 3: Identifying Claws And Front Floor Carpet
        G05414758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Remove the rear floor service hole cover.
        Fig 4: Locating Rear Floor Service Hole Cover
        G05414759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Disconnect the fuel pump connector.
      7. Start the engine.
      8. After the engine stops, turn the ignition switch off.

        HINT:

        DTC P0171/25 (fuel problem) may be detected.

      9. Crank the engine again. Check that the engine does not start.
      10. Remove the fuel tank cap to discharge pressure from the fuel tank.
      11. Disconnect the cable from the negative (-) battery terminal.
      12. Reconnect the fuel pump connector.
      13. Install the rear floor service hole cover.
        Fig 5: Locating Rear Floor Service Hole Cover
        G05414759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      14. Install the front floor carpet and the 3 clips. (w/ rear No. 2 seat)
        Fig 6: Locating Front Floor Carpet And Clips
        G05414757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      15. Engage the 3 claws to install the front floor carpet. (w/o rear No. 2 seat)
      16. Install the rear No. 1 seat assembly (for LH side) (See INSTALLATION ).
      17. Install the rear No. 1 seat assembly (for RH side) (See INSTALLATION ).
  2. PRECAUTIONS 
    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.
    Fig 7: Identifying Claws And Front Floor Carpet
    G05414758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. FUEL LINE 
    1. When disconnecting a high pressure fuel line, a large amount of gasoline will spill out, so observe the following procedures:
      1. Discharge fuel system pressure.
      2. Disconnect the fuel pump tube (See REMOVAL ).
      3. Drain the fuel that remains in the fuel pump tube.
      4. To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag.
      5. Put a container under the connectors.
      Fig 8: Covering Fuel Pump Main Tube From Plastic Bag
      G04974866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe these precautions when disconnecting the fuel tube connector.
      1. Remove the fuel pipe clamp.
      2. Check whether there is any dirt in the pipe around the connector before disconnecting it and remove the dirt as necessary.
        Fig 9: Identifying Fuel Pipe Clamp
        G05414764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the connector from the pipe by hand.
        NOTE: Be sure to disconnect the connector by hand.
      4. If the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.
        NOTE: Be sure to disconnect the connector by hand.
        Fig 10: Pushing Fuel Tube Connector (Quick Type A)
        G04974876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Check that there is no dirt or other foreign objects on the sealing surface of the disconnected pipe. Clean the surfaces if necessary.
      6. Do not damage the disconnected pipe or connector. Prevent entry of foreign objects by covering them with a plastic bag.
      Fig 11: Covering Pipe And Connector With Plastic Bag
      G04974877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Observe the following precautions when connecting the fuel tube connectors (Quick Type A):
      1. Check if there is any damage or foreign objects on the connecting parts of the pipes.
      2. Line up the 2 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.
      4. Check for fuel leaks.
      Fig 12: Push Pipe Into Connector
      G04974878Courtesy 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.
        NOTE: Be sure to disconnect the connector by hand.
        Fig 13: Detaching Claws Of Connector Retainer
        G04974879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. If the connector and pipe are stuck, push and pull on the connector while holding the pipe by hand. Pull the 2 pipes apart to separate the connector.
        NOTE: Be sure to disconnect the connector by hand.
      4. Check if there is any dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the sealing surfaces if necessary.
        Fig 14: Checking Connector Connection
        G04974880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Do not damage the disconnected pipe or connector. Prevent entry of foreign objects by covering them with a plastic bag.
      Fig 15: Covering Connector And Pipe With Plastic Bag (Quick Type B)
      G04974881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Observe the following precautions when connecting the fuel tube connector (Quick Type B):
      1. Line up the 2 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.
      2. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
      3. Check for fuel leaks.
      Fig 16: Disconnecting Fuel Tube Connector (Quick Type B)
      G04974882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Observe the following precautions when handling a nylon tube:
      CAUTION:
      • Do not twist the connector 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 pinch or kink the nylon tubes to prevent fuel leakage.
  4. INJECTOR 
    1. Install the injector to the delivery pipe and the lower intake manifold as shown in the illustration.
      NOTE: Before installing the injector, be sure to apply appropriate lubricant or gasoline where the delivery pipe or cylinder head contacts the injector O-rings.
      Fig 17: Identifying Injector Components
      G05414772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe the following precautions when removing and installing the fuel injectors:
      1. Never reuse an O-ring.
      2. When placing a new O-ring on the injector, do not damage the O-ring.
      3. Coat a new O-ring with spindle oil or gasoline before installing it.
        NOTE: Do not use engine oil, gear oil or brake fluid.
        Fig 18: Identifying Injector O-Ring
        G04974986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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.
  6. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs (See ON-VEHICLE INSPECTION ).
    Fig 19: Locating Fuel Suction Tube
    G05414774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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