Fuel System: Precaution

PRECAUTION
1. Before working on the fuel system, disconnect the negative (-) battery cable.
2. Do not smoke or work near fire when handling the fuel system.
3. Keep gasoline away from rubber or leather parts.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Before removing the fuel system parts, take precautions to prevent gasoline spillage.
- As some pressure remains in the fuel line even after taken precautions to prevent gasoline spillage, use a shop rag to prevent gasoline splashes when disconnecting the fuel line.
1. Remove the circuit opening relay from the instrument panel junction block.
2. Start the engine. After the engine stopped, turn the ignition switch OFF.
  HINT:
  
  Possibly DTC P0171 (system too lean) will be set.
3. Check that the engine does not start.
4. Remove the fuel tank cap, and let the air out of the fuel tank.
  
  Fig 1: Removing Circuit Opening Relay From Instrument Panel Junction Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the negative (-) battery cable.
6. Reinstall the circuit opening relay.
FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures.
  1. Discharge the pressure in the fuel system.
  2. Disconnect the fuel pump tube. (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
  3. Drain the fuel remaining inside the fuel pump tube.
  4. Cover the disconnected fuel pump tube with a vinyl or plastic bag to prevent damage and intrusion of foreign objects.
  5. Place a tray under the vehicle or point of disconnection to catch any fuel that may spill.
    
    Fig 2: Covering Disconnected Fuel Pump Tube With Vinyl Or Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Take the following precautions when removing and installing the fuel injectors.
  NOTE: Never reuse the O-ring.
  1. When installing a new O-ring onto the injector, be careful not to damage it.
  2. Coat the new O-ring with grease or gasoline before installing. Never use engine oil, gear oil or brake oil.
    
    Fig 3: Identifying Precautions For Installing O-Ring Onto Injector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the injector onto the delivery pipe and cylinder head as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline to the place where the delivery pipe comes into contact with the O-ring of the injector.
  
  Fig 4: Installing Injector Onto Delivery Pipe & Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Take these precautions when disconnecting the fuel tube connectors.
  1. Disconnect the fuel pipe clamp from the connector.
  2. Check the pipe and around the connector for dirt or mud before disconnecting them and remove the dirt if necessary.
    
    Fig 5: Identifying Precautions For Disconnect Fuel Pipe Clamp From Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the connector from the hose while pinching part A with your fingers as shown in the illustration.
    
    Fig 6: Identifying Precautions For Disconnect Connector From Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. If the connector and pipe are stuck, pinch the fuel pipe with your fingers, then push and pull the connector to release and disconnect the fuel tube connector. Do not use any tools.
  5. If there is dirt or any other substance on the sealing surface that might interfere with the seal, clean the area thoroughly before assembling.
    
    Fig 7: Identifying Precautions For Disconnect Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Cover the disconnected fuel tube connector and pipe with a vinyl or plastic bag to prevent damage and intrusion of foreign objects.
    
    Fig 8: Covering Disconnected Fuel Tube Connector & Pipe With Vinyl Or Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Take these precautions when connecting the fuel tube connectors.
  1. Check the connected part of the pipe for damage or foreign objects.
  2. Align 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 little amount of fresh engine oil to the tip of the pipe.
    
    Fig 9: Connecting Fuel Tube Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After finishing the connection, check that the pipe and connector are securely connected by pulling them.
  4. Install the fuel pipe clamp onto the connector.
  5. Check for fuel leaks.
    
    Fig 10: Checking That Pipe & Connector Are Securely Connected By Pulling Them
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR FUEL LEAKS
1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (See ON-VEHICLE INSPECTION )