Fuel System (2AZ-FE): Precaution

CAUTION:

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

DISCHARGE FUEL SYSTEM PRESSURE CAUTION:
CAUTION:
- Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
- Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.
Fig 1: Removing Circuit Opening Relay From R/B Sub-Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the circuit opening relay from the R/B sub-assy.
2. Start the engine. After the engine has stopped, turn the ignition switch OFF.
  HINT:
  
  There is a case that DTC P0171 (system to lean) is output.
3. Check that the engine does not start.
4. Remove the fuel tank cap, and let the air out of the fuel tank.
5. 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. Perform step 2 to prevent gasoline from spilling out.
  2. Put a container under the connection.
  3. Disconnect the fuel pump tube (see REPLACEMENT ).
  4. Drain the fuel remained inside the fuel pump tube.
  5. To protect the disconnected fuel pump tube from damage and contamination, cover it with a vinyl bag.
  Fig 2: Identifying Fuel Pump Tube Covered With Vinyl Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Observe these precautions when removing and installing the injector.
  1. Never reuse O-rings.
  2. When placing a new O-ring on the injector, take care not to damage it.
  3. Coat a new O-rings with grease or gasoline before installing. Never use engine, gear or brake oil.
  Fig 3: Identifying Precautions For Removing And Installing Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe touches the O-ring of the injector.
  
  Fig 4: Installing Injector To Delivery Pipe And Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe these precautions when disconnecting the fuel delivery pipe.
  HINT:
  
  The structure of the metallic connector is shown as left.
  1. Remove the fuel pipe clamp No. 2.
    
    Fig 5: Identifying Precautions For Disconnecting Fuel Delivery Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Find 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. SST 09268-21010
    
    Fig 6: Assembling SST To Connection
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector.
  5. Slide SST and the connector together towards the fuel tube assembly.
  Fig 7: Aligning Retainers Inside Connector With SST Chamfered Parts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Observe these following precautions when disconnecting the fuel tube connector (quick type).
  1. Remove the fuel pipe clamp No. 1.
  2. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
    
    Fig 8: Removing Fuel Pipe Clamp No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration.
    
    Fig 9: Disconnecting Connector From Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. If the connector and the pipe are stuck, pinch the fuel pipe, push and pull the connector to disconnect and pull it out. Do not use any tools.
  5. Inspect for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
    
    Fig 10: Disconnecting Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. To protect the disconnected pipe and connector from damage and contamination, cover it with a vinyl bag.
  Fig 11: Identifying Pipe And Connector Covered With Vinyl Bag
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FUEL LEAK
1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see ON-VEHICLE INSPECTION ).