Fuel System: Precaution

PRECAUTION
1. Before working on the fuel system, disconnect the battery negative terminal.
2. Do. not work on the fuel system near fire. Never smoke during the work.
3. Keep rubber and leather parts away from gasoline.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Before removing fuel system parts, take precautions to prevent gasoline spillage.
- As some pressure remains in the fuel line even after taking precautions to prevent gasoline spillage, use a shop rag to prevent gasoline splashes when disconnecting the fuel line.
1. Disconnect the battery negative terminal.
2. Remove the rear seat cushion (see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (FF) , REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (4WD) ).
3. Remove the rear floor service hole cover (see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (FF) , REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (4WD) ).
4. Disconnect the fuel pump connector.
  
  Fig 1: Disconnecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the engine wire (battery negative terminal). Torque: 5.4 Mm (55 kgf.cm, 48 in..lbf)
6. Start the engine.
7. After the engine stops, turn the ignition switch to OFF.
  HINT:
  
  DTC P0171 (system to lean) may be present.
8. Crank the engine again, and check that the engine does not start,
9. Remove the fuel tank cap and discharge the pressure in the fuel tank completely,
10. Disconnect the battery negative terminal,
11. Connect the fuel pump connector.
12. Install the rear floor service hole cover (see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (FF) , REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (4WD) ).
13. Install the rear seat cushion (see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (FF) , REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (4WD) ).
14. Connect the battery negative terminal.
  Torque: 5.4 N.m (55 kgf.cm, 48 In..lbf)
  
  Fig 2: Connecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 (step 2).
  2. Disconnect the fuel tube (see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (FF) , REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (FUEL TANK ASSY (FF)) REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (4WD) , REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY (FUEL TANK ASSY (4WD)) ).
  3. Release the pressure remaining in the fuel tank main tube.
  4. Cover the disconnected fuel tank main tube (fuel tube joint and fuel tube connector) with a vinyl bag to prevent damage and the intrusion of foreign objects.
  5. Put a container under the connection.
    
    Fig 3: Covering Disconnected Fuel Tank Main Tube With Vinyl Bag
    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 onto the fuel injector.
  3. Before installing a new O-ring, apply gasoline or spindle oil onto the fuel injector.
    NOTE: Do not use engine oil, gear oil or brake oil.
    
    Fig 4: Precautions When Removing And Installing Fuel Injector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install the fuel injector onto the fuel delivery pipe and cylinder head as illustrated.
    NOTE: Apply gasoline or spindle oil to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector.
    
    Fig 5: Installing Fuel Injector Onto Fuel Delivery Pipe And Cylinder Head
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Take the following precautions when disconnecting the fuel tube connector (metallic type).
  HINT:
  
  The structure of the fuel tube connector is as shown in the illustration.
  1. Check the fuel tube connector and pipe for dirt and mud before removing the fuel tube connector.
    If dirty, wipe them with a shop rag.
    
    Fig 6: Identifying Structure Of Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the fuel pipe clamp No. 2. (1ZZ-FE)
    NOTE: Do not reuse the fuel pipe clamp that has been removed.
    
    Fig 7: Removing Fuel Pipe Clamp No. 2. (1ZZ-FE)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Hold the metallic connector of the fuel tube assembly, then pull it out of the pipe and hold it as it is.
  4. Assemble SST to the connection as shown.
    SST 09268-21010
    
    Fig 8: Assembling SST To Connection
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Turn SST to align the retainer inside the fuel tube connector with chamfered part of SST. Insert SST into the fuel tube connector.
  6. Hold SST in the position above, then push the fuel tube connector towards SST. Mount the retainer of the fuel tube connector onto the chamfered part of SST.
  7. Slide SST and the fuel tube connector together towards the fuel tube connector until they make a "click" sound.
    
    Fig 9: Mounting Retainer Of Fuel Tube Connector Onto Chamfered Part Of SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Take the following precautions when disconnecting the fuel tube connector (quick type A).
  1. Remove the fuel pipe clamp No. 1.
  2. Check if there is any dirt and mud on the pipe and around the connector before disconnecting them and clean them away.
    
    Fig 10: Locating Fuel Tube Connector (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Be sure to disconnect the connector by hand.
  4. When the connector and pipe are stuck, pinch the retainer by hand, then pull the connector out of the pipe.
    NOTE: Do not use any tool.
  5. Check if there is any dirt on the seal surface of the disconnected pipe and clean it away.
    
    Fig 11: Disconnecting Connector By Hand
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Cover the disconnected pipe and connector with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 12: Covering Disconnected Pipe And Connector With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Take the following precautions when connecting the fuel tube connector (quick type A).
  1. Align the axis of the connector with axis of the pipe, and push the connector in until the retainer makes a "click" sound. If the connections is tight, apply a small amount of new engine oil to the tip of the pipe.
  2. After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
    
    Fig 13: Connecting Fuel Tube Connector (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install the fuel pipe clamp.
  4. Check if there is any fuel leakage.
    
    Fig 14: Locating Fuel Tube Connector (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Take the following precautions when removing the fuel tube connector (type B).
  HINT:
  
  The structure of the fuel tube connector is as shown in the illustration.
  1. Check the fuel tube connector and pipe for dirt and mud before removing the fuel tube connector. If dirty, wipe it with a shop rag.
    
    Fig 15: Identifying Structure Of Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and push it down as shown in the illustration.
  3. Pull the fuel tank main tube out of the pipe.
    
    Fig 16: Removing Lock Claws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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.
    
    Fig 17: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Never use any tools.
  5. After removing the fuel tube, check the sealing surface of the pipe for dirt and mud.
    If dirty, wipe it with a shop rag.
  6. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 18: Covering Disconnected Fuel Tube Connector And Pipe With Vinyl Bag
    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 the fuel tube connector in until it comes into contact with the seat, then push the retainer in until to the claws lock.
    
    Fig 19: Aligning Fuel Tube Connector With Pipe
    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 20: Checking Fuel Tube Connector And Pipe Are Securely Connected
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Take the following precautions when disconnecting the fuel tube connector (quick type C).
  1. Check the pipe and around the connector for dirt and mud before disconnecting them. Clean them if necessary.
  2. Remove the checker of the fuel tube connector from the pipe.
  3. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and slide it as shown in the illustration.
  4. Check the sealing surface of the disconnected pipe for dirt and mud. Clean them away if necessary.
  5. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects.
    
    Fig 21: Removing Lock Claws Of Fuel Tube Connector (Quick Type C)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Take the following precautions when connecting the fuel tube connector (quick type C).
  1. Check the connected part of the pipe for any damage and foreign objects.
  2. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a light coat of fresh engine oil to the tip of the pipe.
  3. Install the checker onto the pipe.
  4. Check for fuel leakage.
    
    Fig 22: Installing Lock Claws Of Fuel Tube Connector (Quick Type C)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Take the following precautions when handling nylon tube.
  1. Pay attention not to turn the connected part of the nylon tube and the quick connector forcibly when connecting them.
  2. Pay attention not to twist the nylon tube.
  3. Do not remove the nylon tube.
  4. Do not forcibly bend the nylon tube.
CHECK FUEL LEAKAGE
1. Check that there are no fuel leakage after doing maintenance anywhere on the fuel system.
  
  Fig 23: Connecting Hand-Held Tester To DLC3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Connect the hand-held tester to the DLC3.
  2. Turn the ignition switch to ON.
    NOTE: Do not start the engine.
  3. Turn the hand-held tester ON.
  4. Select the following menu items: DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/FUEL PUMP/SPD.
  5. If you have no hand-held tester, connect the positive (+) lead from the battery to terminal 5 of the connector, and the negative (-) lead to terminal 4.
    
    Fig 24: Connecting Positive (+) Lead From Battery To Terminal Of Connector, And Negative (-) Lead To Terminal (FF)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    These tests must be done quickly (for less than 10 seconds) to prevent coil burnout.
    
    Keep the fuel pump as for away from the battery as possible.
    
    Always do the switching at the battery side.
  6. Check that there are no leakage from any parts of the fuel system.
  7. Turn the hand-held tester OFF.
  8. Turn the ignition switch to LOCK.
  9. Disconnect the hand-held tester from the DLC3
    
    Fig 25: Connecting Positive (+) Lead From Battery To Terminal Of Connector, And Negative (-) Lead To Terminal (4WD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002