Fuel System: Precaution

BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY
DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM
KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
DISCHARGE FUEL SYSTEM PRESSURE
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.
  
  Fig 1: Connecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FUEL SYSTEM
1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out. Follow these procedures:
  1. Perform step ( 4).
  2. Disconnect the fuel tube.
  3. Drain the fuel remaining inside the fuel tube.
  4. Cover the fuel tube with a plastic bag to protect it from damage and foreign objects.
  5. Place a container under the connection.
2. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, follow these procedures:
  1. Always use 2 new gaskets.
  2. Tighten the union bolt with your hands.
    
    Fig 2: Tightening Union Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using SST, tighten the union bolt to the specified torque.
    SST 09612-24014 (09617-24011)
    
    Torque:
    - 39 N.m (397 kgf.cm, 29 ft.lbf)
    - 33 N.m (337 kgf.cm, 24 ft.lbf) for use with SST
  HINT:
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
  
  Fig 3: Tightening Union Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. When connecting the flare nut on the high pressure pipe union, follow 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.
    SST 09023-38401
    
    Torque:
    - 35 N.m (357 kgf.cm, 26 ft.lbf)
    - 28 N.m (286 kgf.cm, 21 ft.lbf) for use with SST
  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: Connecting Flare Nut On High Pressure Pipe Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Follow 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 installation. Never use engine, gear or brake oil.
    
    Fig 5: Removing & Installing Injector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the injector to the delivery pipe and lower intake manifold as shown in Fig 6. Before installing the injector, apply spindle oil or gasoline to where the delivery pipe and intake manifold contact the O-ring.
6. Follow these precautions when disconnecting the fuel tube connector (quick type):
  1. Check for dirt and foreign matter in the pipe and around the connector. Clean if necessary and then disconnect the connector.
    
    Fig 6: Installing Injector To Delivery Pipe & Lower Intake Manifold
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Disconnect the connector with your hands.
  3. If the pipe and connector are stuck together, push and pull the connector until they separate. Do not use tools to separate the pipe and connector.
    
    Fig 7: Separating Connector By Pushing & Pulling (Quick Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check for dirt and foreign matter on the pipe seal surface. Clean if necessary.
  5. Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
7. Follow 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 too tight, apply a small amount of new engine oil on the tip of the pipe.
    
    Fig 8: Pushing In Connector (Quick Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check if the pipe and the connector are securely connected by pulling them.
  3. Check that fuel leakage does not occur.
8. Follow these precautions when handling the nylon tube.
  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 covering the nylon tube.
  4. Do not bend the nylon tube.
    
    Fig 9: Handling Nylon Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR FUEL LEAKS
1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.
  1. Connect the hand-held tester to the DLC3.
    
    Fig 10: Connecting Hand-Held Tester To DLC3
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Turn the ignition switch ON, and push the hand-held tester main switch ON.
    NOTE: Do not start the engine.
  3. Select the ACTIVE TEST mode on the hand-held tester.
    HINT:
    
    Refer to the hand-held tester operator's manual for further details.
  4. Check that there are no leaks from the fuel system.
  5. Turn the ignition switch OFF.
  6. Disconnect the hand-held tester from the DLC3.