Fuel System: Precaution

CAUTION:

Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
Do not smoke or be near an open flame when working on the fuel system.
Keep gasoline away from rubber and leather parts.

DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
- After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
1. Remove the engine room side cover LH.
2. Remove the engine room relay block cover.
3. Remove the circuit opening relay (C/OPN).
4. Start the engine. After the engine has stopped on its own, turn the engine switch off.
  HINT:
  
  If DTC P0230 is output, clear the DTC (See DTC CHECK/CLEAR ).
5. Crank the engine, then check that the engine does not start.
6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
7. Disconnect the cable from the negative (-) battery terminal.
  NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  
  Fig 1: Identifying Circuit Opening Relay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the circuit opening relay (C/OPN).
9. Install the engine room relay block cover.
10. Install the engine room side cover LH.
FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures.
  1. Perform the "Discharge Fuel System Pressure" procedures above.
  2. Put a container under the connecting part of the pressure line.
  3. Slowly loosen the connection.
  4. Disconnect the connection.
  5. Plug the connection with a rubber plug and cover it with a plastic bag.
2. Observe these precautions when installing the injectors:
  - Never reuse the O-ring.
  - When placing a new O-ring on the injector, do not damage it.
  - Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil.
    
    Fig 2: Covering Connection With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the injector to the delivery pipe and cylinder head as shown in the illustration.
  NOTE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector.
  
  Fig 3: Identifying Delivery Pipe, O-Ring, Injector And Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe these precautions when disconnecting the fuel tube connector (for quick type A).
  1. for Fuel Pipe Clamp Type:
    Remove the fuel pipe clamp from the fuel tube connector.
    
    Fig 4: Identifying Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration.
  3. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
    
    Fig 5: Lifting Up Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Pinch the connector and disconnect the connector and pipe.
    If the connector and the pipe are stuck together, pinch the connector, then push and pull the pipe to disconnect the pipe and pull it out.
    
    NOTE: Do not use any tools in this procedure.
  5. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
    
    Fig 6: Disconnecting Connector And Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
    
    Fig 7: Covering Disconnected Pipe And Connector With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Observe these precautions when disconnecting the fuel tube connector (for quick type B).
  1. Check that there is no damage or foreign matter on the part of the pipe that contacts the connector.
    
    Fig 8: Disconnecting Fuel Tube Connector (For Quick Type B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe.
    HINT:
    
    If the connector and pipe are stuck, pinch the fuel pipe by hand, and push and pull the connector to disconnect it.
    
    NOTE: Do not use any tools in this procedure.
  3. Check for foreign matter on the seal surface of the disconnected pipe. Clean it if necessary.
    
    Fig 9: Detaching Claws Of Connector Retainer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. To protect the disconnected pipe and connector from damage and foreign matter, cover it with a plastic bag.
    
    Fig 10: Covering Disconnected Pipe And Connector With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Observe these precautions when connecting the fuel tube connector (for quick type B).
  1. Check for foreign matter on the pipe and around the connector before connecting it. Clean it if necessary.
  2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector, and push up on the retainer.
    
    Fig 11: Connecting Fuel Tube Connector (For Quick Type B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After connecting the pipe and connector, try to pull them apart to confirm that they are securely connected.
    
    Fig 12: Connecting Pipe And Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Observe these precautions when connecting the fuel tube connector (for quick type A).
  1. Check that there is no damage or contamination in the connection part of the pipe.
  2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
    
    Fig 13: Pushing Pipe Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected.
    
    Fig 14: Pulling Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. for Fuel Hose Connector Cover Type:
    Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
    
    Fig 15: Pushing Down On Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. for Fuel Pipe Clamp Type:
    Install the fuel pipe clamp to the connector.
  6. Check that there is no fuel leakage.
CHECK FOR FUEL LEAK
1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system (See ON-VEHICLE INSPECTION ).
  
  Fig 16: Identifying Fuel Pipe Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002