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Fuel System: Precaution

  1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY 
  2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 
  3. KEEP GASOLINE AWAY FROM RUBBER AND LEATHER PARTS 
  4. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
    Fig 1: Disconnecting Fuel Pump Connector
    G02998959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel pump connector.
    2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
    3. Disconnect the negative (-) terminal cable from the battery.
    4. Connect the fuel pump connector.
  5. FUEL SYSTEM 
    1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe these procedures:
      1. Perform step ( 4) above.
      2. Disconnect the fuel tube.
      3. Drain the fuel remaining inside the fuel tube.
      4. Protect the disconnected fuel tube from damage and foreign material by covering it with a plastic bag.
      5. Put a container under the connection.
    2. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures:
      1. Always use 2 new gaskets.
      2. Tighten the union bolt by hand.
      3. Using SST, tighten the union bolt to the specified torque.
      1. SST 09612-24014 (09617-24011)
      Fig 2: Connecting Union Bolt
      G02998960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 
      2. 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 
      3. 39 N.m (400 kgf.cm, 29 ft.lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

      Fig 3: Tightening Union Bolt using SST
      G02998961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. When connecting the flare nut on the high pressure pipe union, observe these procedures:
      1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand.
      2. Using SST, tighten the flare nut to the specified torque.
      1. SST 09023-38401
      1. Torque: 32 N.m (330 kgf.cm, 24 ft.lbf) 
      NOTE: Do not rotate the fuel main tube when tightening the flare nut.

      HINT:

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

      Fig 4: Tightening Nut
      G02998962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Observe these precautions when removing and installing the injector.
      1. Never reuse the O-ring.
      2. When placing a new O-ring on the injector, take care not to damage it.
      3. Coat a new O-ring with spindle oil or gasoline before installing. Never use engine, gear or brake oil.
      Fig 5: Identifying Poper Location Delivery Pipe
      G02998963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the injector to the delivery pipe and the lower intake manifold as shown in the illustration. Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe or intake manifold touches O-ring of the injector.
    6. Observe these precautions when disconnecting the fuel tube connector (quick type):
      Fig 6: Installing Injector To Delivery Pipe
      G02998964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check for dirt contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
      2. Disconnect the connector with your hands.
      3. If the pipe and connector are stuck together, push and pull the connector until it comes free. Do not use tools to separate the pipe and connector.
      4. Check for dirt contamination on the pipe seal surface. Clean if necessary.
      5. Put the pipe and connector ends in vinyl bags to prevent damage and dirt contamination.
      Fig 7: Pulling Connector
      G02998965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Observe these precautions when connecting the fuel tube connector (quick type):
      1. Match the axis of the connector with the axis of the pipe, and push in the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of new engine oil on the tip of the pipe.
      2. After finishing the connection, check if the pipe and connector are securely connected by trying to pull them apart.
      3. Check if there is any fuel leakage.
    8. Observe these precautions when handling the nylon tube.
    Fig 8: Connecting Fuel Tube Connector
    G02998966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Do not forcefully twist the nylon tube when connecting it to the quick connector.
    2. Do not damage the nylon tube.
    3. Do not remove the EPDM protector on the outside of the nylon tube.
    4. Do not bend the nylon tube.
    Fig 9: Pulling Connector
    G02998967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CHECK FUEL LEAK 
    1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
    1. Connect the hand-held tester (with CAN VIM) to the DLC3.
    2. Turn the ignition switch ON and hand-held tester main switch ON.
      NOTE: Do not start the engine.
      Fig 10: Connecting Hand-Held Tester DLC3
      G02998968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Select the ACTIVE TEST mode on the hand-held tester.
    4. Please refer to the hand-held tester operator's manual for further details.
    5. Check that there are no leaks from any part of the fuel system.
    6. Turn the ignition switch to LOCK.
    7. Disconnect the hand-held tester from the DLC3.
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