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Fuel System: Precaution

  1. PRECAUTION 
    1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.
    2. Do not smoke or work near fire when working on the fuel system.
    3. Keep gasoline away from rubber or leather parts.
  2. WORK FOR PREVENT GASOLINE FROM SPILLING OUT 
    CAUTION:
    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
    • Even after discharging the fuel pressure, place a shop rag or piece of cloth over fittings to prevent fuel splashing on yourself or in the engine compartment when separating the fittings.
    1. Remove the circuit opening relay from the engine room relay block.
    2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.

      HINT:

      There is a case that DTC P0171 (system too lean) is output.

    3. Check that the engine does not start.
      Fig 1: Identifying C/OPN Relay
      G04962522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel tank cap, and let the air out of the fuel tank.
    5. Disconnect the negative (-) terminal cable from the battery.
    6. Reinstall the circuit opening relay.
  3. FUEL SYSTEM 
    1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures:
      1. Disconnect the fuel pump tube (See REMOVAL ).
      2. Drain the fuel remained inside the fuel pump tube.
      3. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
      4. Place a container under the connection.
      Fig 2: Covering Bag Pipe And Connector With Plastic
      G04962523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe the following procedures:
      1. Always use new gaskets.
      2. Tighten the union bolt by hand.
        Fig 3: Identifying Union Bolt Gaskets
        G04962524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using SST, tighten the union bolt to the specified torque.

        SST 09612-24014 (09617-24011) 

        Torque: for use with SST 

        33 N*m (340 kgf*cm, 24 ft.*lbf) 

        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 4: Identifying Torque Wrench Fulcrum Length Of 30 cm (11.81 in.)
        G04962525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Observe the following precautions when removing and installing the injectors:
      1. Never reuse the O-ring.
      2. When placing a new O-ring on the injector, do not damage the O-ring.
      3. Coat the new O-ring with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake fluid.
      Fig 5: Precautions For Removing And Installing Injectors
      G04962526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the injector to the delivery pipe and lower intake manifold, as shown in the illustration.
      NOTE: Before installing the injector, apply spindle oil or gasoline where the delivery pipe or intake manifold contacts the O-ring of the injector.
      Fig 6: Identifying Injector Installed To The Delivery Pipe And Lower Intake Manifold
      G04962527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Observe the following precautions when disconnecting the fuel tube connector (Quick type A):
      1. Remove the fuel pipe clamp No. 1.
      2. Check that there is no dirt on the pipe and around the connector before disconnecting them. Clean them if necessary.
      3. Disconnect them by hand.
        Fig 7: Identifying Fuel Pipe Clamp No. 1
        G04962528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. When the connector and the pipe are stuck, pinch the fuel pipe with your fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out of the pipe.
      5. Check that there is no dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary.
      6. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
      Fig 8: Identifying Connector (Quick Type A)
      G04962529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Observe the following precautions when connecting the fuel tube connector (Quick Type A):
      1. Check that there is no damage or foreign objects in the connected part of the pipe.
      2. Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.
        Fig 9: Pushing Into Connector (Quick Type A)
        G04962530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After finishing the connection, check if the pipe and the connector are securely connected by pulling them.
      4. Check for fuel leaks.
      Fig 10: Pulling Connector (Quick Type A)
      G05264842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Observe the following precautions when disconnecting the fuel tube connector (Quick type B):
      Fig 11: Identifying Connector (Quick Type B)
      G04962532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
      2. Disconnect them by hand.
      3. When the connector and the pipe are stuck, push and pull the connector. Disconnect and pull it out. Do not use any tool at this time.
      4. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary.
      5. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
    8. Observe the following precautions when connecting the fuel tube connector (Quick type B):
      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. In case that the connection is tight, apply a small amount of new engine oil to the tip of the pipe.
        Fig 12: Pushing In Fuel Tube Connector (Quick Type B)
        G04962533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. After finishing the connection, check if the pipe and the connector are securely connected by pulling them.
      3. Check for fuel leaks.
      Fig 13: Pulling Out Fuel Tube Connector (Quick Type B)
      G04962534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Observe the following precautions when disconnecting the fuel tube connector (Quick type C):
      1. Pull the fuel hose connector cover up to release the lock.
      2. Check that there is no dirt in the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
      3. Be sure to disconnect them by hand.
        Fig 14: Identifying Fuel Hose Connector Cover
        G05264846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. When the connector and the pipe are stuck, pinch the fuel pipe between the hands, and push and pull the connector. Disconnect and pull it out. Do not use any tool at this time.
      5. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary.
      6. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
      Fig 15: Identifying Connector (Quick Type C)
      G04962536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Observe the following precautions when connecting the fuel tube connector (Quick Type C):
      1. Check that there is no damage or foreign objects in the connected part of the pipe.
      2. Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.
        Fig 16: Pushing Into Connector (Quick Type C)
        G04962537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After finishing the connection, check if the pipe and the connector are securely connected by pulling them.
        Fig 17: Pulling Out Connector (Quick Type C)
        G04962538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Lock the fuel hose connector cover.

        HINT:

        If the fuel tube is not completely connected, the half connection prevention connector prevents the fuel hose connector cover from being locked.

      5. Check for fuel leaks.
    11. Observe the following precautions when handling a nylon tube:
    Fig 18: Identifying Fuel Hose Connector Cover
    G04962539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION:
    • Do not twist the connection part of the nylon tube and the quick connector by force when connecting them.
    • Do not twist the nylon tube.
    • Do not remove the EPDM protector on the outside of the nylon tube.
    • Do not close the piping with the nylon tube by bending it.
  4. CHECK FOR FUEL LEAK 
    1. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance (See ON-VEHICLE INSPECTION ).
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