Fuel System: Precaution

PRECAUTION
1. Before working on fuel system, disconnect negative (-) battery cable.
2. Do not smoke or work near fire when handling the fuel system.
3. Keep gasoline away from rubber or leather parts.
4. Replace the fuel tank with a new one if the vehicle has been damaged, resulting in airbag deployment.
DISCHARGE FUEL SYSTEM PRESSURE
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.
1. Remove the circuit opening relay from the engine room relay block.
  
  Fig 1: Removing Circuit Opening Relay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Start the engine. After the engine stopped, turn the ignition switch OFF.
  HINT:
  
  It is possible that DTC P0171 (system too lean) will be set.
3. Check that the engine does not start.
4. Remove the fuel tank cap, and let the air out of the fuel tank.
5. Disconnect the negative (-) battery cable.
6. 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. Discharge fuel system pressure. (See step 2)
  2. Disconnect the fuel pump tube. (See DISASSEMBLY ).
  3. Drain the fuel that remained inside the fuel pump tube.
  4. Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
    
    Fig 2: Covering Disconnected Fuel Pump Tubes With Vinyl Or Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Place a tray under the vehicle or point of disconnection to catch any fuel that may spill.
2. Observe the following precautions when removing and installing fuel injectors.
  NOTE: Never reuse the O-ring.
  1. When installing a new O-ring to the injector, be careful not to damage the injector.
  2. Coat the new O-ring with grease or gasoline before installing. Never use engine oil, gear oil or brake oil.
    
    Fig 3: Precautions Of Fuel Injectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the injector to the delivery pipe and the cylinder head as shown in Fig 4 . Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe contacts 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 tube connector.
  1. Disconnect the fuel pipe clamp from the connector.
    
    Fig 5: Disconnecting Fuel Pipe Clamp From Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that there is no dirt or mud on the pipe and around the connector before disconnecting them. Clean them if necessary.
  3. Disconnect the connector from the hose while pinching part A with fingers as shown in Fig 6 .
    
    Fig 6: Disconnecting Connector From Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. When the connector and the pipe are stuck, push and pull the connector to release and pull the connector out from the pipe carefully.
    
    Fig 7: Pushing And Pulling Connector To Release
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Inspect that there is no dirt or mud on the sealing surface of the disconnected pipe. Clean it away if necessary.
  6. To prevent the disconnected pipe and connector from being damaged and foreign objects from being introduced, cover them with a vinyl or plastic bag.
    
    Fig 8: Covering Pipe And Connector With Vinyl Or Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Observe these precautions when connecting the fuel tube connectors (Quick Type):
  1. Check that there is no damage or foreign objects in the connected 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 little amount of fresh engine oil on the tip of the pipe.
    
    Fig 9: Pushing Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After having finished connection, check if the pipe and the connector are securely connected by pulling on them.
    
    Fig 10: Checking Pipe And Connector Are Secure By Pulling
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check for fuel leaks.
CHECK FOR FUEL LEAKS
1. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (See ON-VEHICLE INSPECTION )