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
WORK FOR PREVENT GASOLINE FROM SPILLING OUT
1. Remove the rear seat cushion.
  (See REMOVAL & INSTALLATION ) , 4WD: ) REMOVAL & INSTALLATION )
2. Remove rear floor service hole cover.
  (See REMOVAL & INSTALLATION ) , (4WD: REMOVAL & INSTALLATION )
3. Disconnect the fuel pump connector.
4. Start the engine. After the engine has stopped on its own, turn the ignition switch to lock.
5. Disconnect negative (-) terminal cable from battery.
6. Connect the fuel pump connector.
  
  Fig 1: Connecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install rear floor service hole cover.
  (See REMOVAL & INSTALLATION ) , 4WD: (REMOVAL & INSTALLATION )
8. Install the rear seat cushion.
  (See REMOVAL & INSTALLATION ), 4WD: (REMOVAL & INSTALLATION )
FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures.
  1. Work for prevent gasoline from spilling out.
  2. Disconnect the fuel tank main tube.
  3. Drain the fuel remained inside the fuel tank main tube.
  4. Protect the disconnected fuel tank main tube from damage and foreign material by covering it with a vinyl bag.
    
    Fig 2: Identifying Fuel Tank Main Tube Covering With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Put a container under the connection.
  Fig 3: Putting Container Under Connection
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Observe these precautions when removing and installing the fuel injector.
  
  Fig 4: Precautions For Removing & Installing Fuel Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Never reuse an O-ring.
  2. When placing a new O-ring on the fuel injector, take care not to damage it in any way.
  3. Coat a new O-ring with spindle oil or gasoline before installing.
  NOTE: Never use engine, gear or brake oil.
3. Install the fuel injector to the fuel delivery pipe and cylinder head, as shown in Fig 5 . Before installing the fuel injector, be sure to apply spindle oil or gasoline on the place where the fuel delivery pipe touches an O-ring of the fuel injector.
  
  Fig 5: Installing Fuel Injector To Fuel Delivery Pipe & Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe these precautions when disconnecting the fuel delivery pipe.
  NOTE: The structure of the metallic connector is shown in Fig 6 .
  
  Fig 6: Identifying Structure Of Metallic Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Remove the EFI fuel pipe clamp. (1ZZ-FE)
    
    Fig 7: Removing EFI Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Get the metallic connector of the fuel tube assembly, pull it out towards the rear and hold it as it is.
  3. Assemble SST to the connection as shown in Fig 8.
    
    Fig 8: Assembling SST To Connection
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    SST 09268-21010
  4. Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector.
    
    Fig 9: Aligning Retainers Inside Connector With SST Chamfered Parts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Slide the SST and the connector together towards the fuel tube assembly.
5. Observe these precautions when disconnecting the fuel tube connector (quick type).
  1. Remove the EFI fuel pipe clamp.
    
    Fig 10: Removing EFI Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.
  3. Be sure to disconnect with hands.
  4. When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out.
    
    Fig 11: Pushing & Pulling Connector For Free To Disconnect
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Do not use any tool at this time.
  5. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.
  6. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
  Fig 12: Identifying Disconnected Pipe & Connector With Vinyl Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Observe these precautions when connecting the fuel tube connector (quick type).
  
  Fig 13: Connecting Fuel Tube Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Match the axis of the connector with axis of the pipe, and push in the connector until retainer makes a "click" sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe.
  2. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
CHECK FUEL LEAK
1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
  1. Connect the hand-held tester to the DLC3.
  2. Turn the ignition switch ON and hand-held test, main switch ON.
  3. Select the active test mode on the hand-held tester.
  4. Please refer to the hand-held tester operator's manual for further details.
  5. If you have no hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.
    
    Fig 14: Connecting Positive (+) & Negative (-) Leads From Battery To Fuel Pump Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Check that there are no leaks from any part of the fuel system.
  7. Turn the ignition switch to LOCK.
  8. Disconnect the hand-held tester from the DLC3.