Fuel System: Precaution

PRECAUTION
1. Before working on the fuel system, disconnect the engine wire No. 2 (battery negative terminal).
2. Do not work on the fuel system near fire. Never smoke during the work.
3. Keep rubber or leather parts away from gasoline.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Before removing the fuel system parts, take precautions to prevent gasoline spill.
- As some pressure remains in the fuel line even after taking precautions to prevent gasoline spill, use a shop rag to prevent gasoline splash when disconnecting the fuel line.
1. Set the vehicle to the "INSPECTION MODE". (See INSPECTION MODE ).
2. Remove the rear floor board No. 2 (see REAR FLOOR BOARD REPLACEMENT ).
3. Remove the deck floor box rear (see DECK FLOOR BOX REAR REPLACEMENT ).
4. Remove the rear floor board No. 3 (see REAR FLOOR BOARD NO. 3 REPLACEMENT ).
5. Disconnect the engine wire No. 3 (battery negative terminal) (see ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
6. Remove the rear seat (see REAR SEAT REMOVAL ).
7. Remove the rear floor service hole cover.
8. Disconnect the fuel pump connector.
9. Connect the engine wire No. 3 (battery negative terminal) (see ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
10. Start the engine.
11. After the engine stops (rough idle), turn the power switch OFF.
  
  Fig 1: Disconnecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  DTC P0171 (system to lean) may be present.
12. Crank the engine again, then check that the engine does not start.
13. Remove the fuel tank cap, then discharge the pressure in the fuel tank completely.
14. Disconnect the engine wire No. 3 (battery negative terminal) (see ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
15. Connect the fuel pump connector.
16. Install the rear floor service hole cover.
17. Install the rear seat (see REAR SEAT INSTALLATION ).
18. Connect the engine wire No. 3 (battery negative terminal) (see NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
19. Install the rear floor board No. 3.
20. Install the deck floor box rear.
21. Install the rear floor board No. 2.
FUEL SYSTEM
1. When disconnecting the high-pressure fuel line, a large amount of gasoline will splash. So take the following precautions.
  1. Discharge the fuel system pressure (see step DISCHARGE FUEL SYSTEM PRESSURE).
  2. Disconnect the fuel pump tube (see step REMOVE FUEL TANK ASSY ).
  3. Drain the pressure remaining in the fuel pump tube.
  4. Cover the disconnected fuel pump tube (fuel tube joint and fuel tube connector) with a vinyl bag to prevent damage and intrusion of foreign objects.
  Fig 2: Cover Disconnected Fuel Pump Tube With Vinyl Bag To Prevent Damage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Take the following precautions when removing and installing the fuel injector.
  1. Do not reuse the O-ring.
  2. Do not damage a new O-ring when installing it to the fuel injector.
  3. Before installing a new O-ring, apply spindle oil or gasoline.
  Fig 3: Precautions While Removing & Installing Fuel Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not use engine oil, gear oil or brake oil.
3. Install the fuel injector to the fuel delivery pipe and cylinder head as illustrated.
  NOTE: Apply spindle oil or gasoline to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector.
  
  Fig 4: Installing Fuel Injector To Fuel Delivery Pipe And Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Take the following precautions when removing the fuel tube connector (Type A).
  1. Check the fuel tube connector and pipe for dirt or mud before removing the fuel tube connector.
    If dirty, wipe it off with a shop rag.
  2. Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe.
    
    Fig 5: Pinch Retainer And Pull Out Fuel Tube Connector From Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If the fuel tube connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector.
    NOTE: Never use any tools.
  4. After removing the fuel tube, check the sealing surface of the pipe for dirt or mud.
    If dirty, wipe it off with a shop rag.
    
    Fig 6: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and intrusion of foreign objects.
    
    Fig 7: Cover Disconnected Fuel Tube Connector And Pipe With Vinyl Bag To Prevent Damage
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Take the following precautions when installing the fuel tube connector (Type A).
  1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound.
    HINT:
    
    If they are connected too tightly, apply a light coat of engine oil to the tip of the pipe, then install the fuel tube connector.
    
    Fig 8: Push Fuel Tube Connector Until Retainer Makes Click Sound
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
    
    Fig 9: Check That The Fuel Tube Connector And Pipe Are Securely Connected
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Take the following precautions when removing the fuel tube connector (Type B).
  1. Check the fuel tube connector and pipe for dirt or mud before removing the fuel tube connector
    If dirty, wipe it off with a shop rag.
  2. Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe.
    
    Fig 10: Pinching Retainer And Pull Out Fuel Tube Connector From Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If the fuel tube connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector.
    NOTE: Never use any tools.
  4. After removing the fuel tube, check the sealing surface of the pipe for dirt or mud.
    If dirty, wipe it off with a shop rag.
    
    Fig 11: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and intrusion of foreign objects.
    
    Fig 12: Cover Disconnected Fuel Tube Connector And Pipe With Vinyl Bag To Prevent Damage
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Take the following precautions when installing the fuel tube connector (Type B).
  1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound.
    HINT:
    
    If they are connected too tightly, apply a light coat of engine oil to the tip of the pipe, then install the fuel tube connector.
    
    Fig 13: Precaution While Installing Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
    
    Fig 14: Check That Fuel Tube Connector And Pipe Are Securely Connected
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR FUEL LEAKS
1. Check that there are no fuel leaks after doing maintenance on the fuel system (see ON-VEHICLE INSPECTION ).