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Fuel System: Precaution: Precaution

  1. BEFORE WORKING ON FUEL SYSTEM 
    1. Do not work near an open flame.
    2. Keep gasoline away from rubber and leather parts.
    3. Discharge the fuel pressure before disconnecting the fuel line to prevent gasoline from spilling out. Refer to the following procedure.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • The DISCHARGE FUEL SYSTEM PRESSURE procedures must be performed before disconnecting any part of the fuel system.
    • After performing the DISCHARGE FUEL SYSTEM PRESSURE procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray.
    1. Remove the rear seat cushion with cover pad subassembly. Refer to REMOVAL - Step 1 .
    2. Remove the rear seat under tray cover. Refer to REMOVAL - Step 2 .
    3. Remove the bench type rear seat cushion assembly. Refer to REMOVAL - Step 3 .
    4. Remove the rear door scuff plate RH. Refer to REMOVAL - Step 15 .
    5. Remove the rear door scuff plate LH. Refer to REMOVAL - Step 16 .
    6. Remove the rear floor service hose cover.
      Fig 1: Identifying Rear Floor Service Hole Cover
      GTY160854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the connector.
      Fig 2: Identifying Connector To Fuel Pump Assembly
      GTY160855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Start the engine. After the engine stops naturally, turn the ignition switch off.

      HINT: 

      DTC P0171 (system too lean) may be set.

    9. Start the engine again and make sure that engine does not start.
    10. Remove the fuel tank cap, and let the air out of the fuel tank.
    11. Connect the connector.
      Fig 3: Identifying Connector To Fuel Pump Assembly
      GTY160855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Install the rear floor service hole cover with new butyl tape.
      Fig 4: Identifying Rear Floor Service Hole Cover With New Butyl Tape
      GTY160860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Install the rear door scuff plate RH. Refer to INSTALLATION - Step 45 .
    14. Install the rear door scuff plate LH. Refer to INSTALLATION - Step 46 .
    15. Install the bench type rear seat cushion assembly. Refer to INSTALLATION - Step 8 .
    16. Install the rear seat under tray cover. Refer to INSTALLATION - Step 9 .
    17. Install the rear seat cushion with cover pad subassembly. Refer to INSTALLATION - Step 2 .
  3. FUEL SYSTEM 
    1. When disconnecting the high-pressure fuel line, a large amount of gasoline will spray out. So take the following precautions:
      1. Discharge the fuel system pressure.
      2. Disconnect the fuel tube.
      3. Drain the fuel remaining inside the fuel pump tube into a container.
      4. Do not damage the disconnected pipe or connector, and prevent entry of foreign matter by covering them with plastic bags.
        Fig 5: Covering Fuel Pump Main Tube From Plastic Bag
        GTY134272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe the following precautions when removing and installing the fuel injector.
      Fig 6: Identifying Correct Installation Of O-Ring
      GTY313205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Do not reuse the O-ring and insulator.
      2. When placing a new O-ring onto the injector, do not damage the O-ring.
      3. Coat the new O-ring with grease or gasoline before installing it. Do not use engine, gear or brake oil.
    3. Install the injector into the delivery pipe and cylinder head, as shown in the illustration. Apply grease or gasoline to the contact surfaces of the injector before installing the injector.
      Fig 7: Identifying Fuel Injector, Insulator, Fuel Delivery Pipe And O-Ring
      GTY162114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Observe the following precautions when disconnecting the fuel delivery pipe (metallic type).

      HINT: 

      The structure of the fuel tube connector is as shown in the illustration.

      1. Check if there is any damage or foreign matter on the connecting parts of the pipes.
      2. Remove the EFI fuel pipe clamp.
        Fig 8: Removing Fuel Pipe Clamp
        GTY313052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Find the metallic connector of the fuel tube assembly.
      4. Assemble SST to the connection as shown in the illustration.
        • SST: 09268-21011 
      5. Turn SST, align the retainers inside the connector with the SST chamfered parts and insert SST into the connector.
      6. Slide SST and the connector together towards the fuel tube assembly.
    5. Observe the following precautions when connecting the fuel tube connector (metallic type).
      Fig 9: Checking Fuel Tube Connector (Metallic Type)
      GTY166138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check if there is any damage or foreign matter on the connecting 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. If the connection is tight, apply a small amount of clean engine oil to the tip of the pipe.
      3. After finishing the connection, check if the pipe and the connector are securely connected by pulling on them.
      4. Install a EFI fuel pipe clamp.
      5. Inspect for fuel leaks.
    6. Observe the following precautions when disconnecting the fuel tube connectors (Quick Type A).
      Fig 10: Claw And EFI Fuel Pipe Clamp
      GTY346375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Release the claw and remove the EFI fuel pipe clamp.
      2. Check that there is no dirt or other foreign matter on the pipe and around the connector before disconnecting them. Clean them if necessary.
      3. Pinch the fuel tube connector, and then disconnect the fuel tube.
        Fig 11: Pinching Connector
        GTY147710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Do not use any tools.

      4. Drain the fuel remaining inside the fuel tube.
      5. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected part.
        Fig 12: Covering Fuel Tube And Fuel Pipe With Plastic Bag
        GTY161692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Observe the following precautions when connecting the fuel tube connectors (Quick Type A).
      Fig 13: Checking Connector Connection
      GTY101695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check if there is any damage or foreign matter on the connecting parts of the pipes.
      2. Line up the two parts of the pipes to be connected, and push them together until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.
      3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
      4. Engage the lock claws and install the EFI fuel pipe clamp.
        Fig 14: Claw And EFI Fuel Pipe Clamp
        GTY346375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Inspect for fuel leaks.
  4. INSPECT FOR FUEL LEAK 
    1. Check that there is no fuel leakage after performing maintenance anywhere on the fuel system (See step  1).
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