Fuel System: 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:
- 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 cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
1. Disconnect the cable from the negative (-) battery terminal.
  NOTE: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. Disconnect the fuel pump connector.
  
  Fig 1: Disconnecting Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the cable to the negative (-) battery terminal.
4. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
  HINT:
  
  DTC P0171/0174 (system too lean) may be set.
5. Crank the engine again, then check that the engine does not start.
6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
7. Connect the fuel pump connector.
FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures.
  1. Discharge the fuel system pressure (see step 1 ).
2. Observe these precautions when connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union.
  1. Always use 2 new gaskets.
    
    Fig 2: Using New Gasket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Tighten the union bolt by hand.
  3. Using SST, tighten the union bolt to the specified torque.
    SST 09612-24014
    
    Torque:
    - 33 N*m (340 kgf*cm, 24 ft.*lbf) for use with SST
    - 39 N*m (400 kgf*cm, 29 ft.*lbf) for use without SST
    HINT:
    
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    
    Fig 3: Tightening Union Bolt Using Torque Wrench
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. When connecting the flare nut on the high pressure pipe union, follow the procedure below:
  1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand.
  2. Using SST, tighten the flare nut to the specified torque.
    SST 09023-12701
    
    NOTE: Do not rotate the fuel filter outlet when tightening the flare nut.
    
    Torque:
    - 34 N*m (345 kgf*cm, 25 ft.*lbf) for use with SST
    - 38 N*m (380 kgf*cm, 28 ft.*lbf) for use without SST
    HINT:
    
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.)
  Fig 4: Tightening Flare Nut Using Torque Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe these precautions when removing and installing the injector.
  1. Never reuse the O-rings.
  2. When placing a new O-ring on the injector, take care not to damage it in any way.
  3. Coat new O-rings with grease or gasoline before installing them. Never use engine, gear or brake oil.
    
    Fig 5: Precautions When Removing & Installing Injector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the injector to the delivery pipe and cylinder head as shown in Fig 6. 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 6: Installing Injector To Delivery Pipe & Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Observe these precautions when disconnecting the fuel tube connector (quick type A).
  1. w/Fuel pipe clamp type:
    Remove the fuel pipe clamp.
    
    Fig 7: Removing Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. w/Fuel hose connector cover type:
    Disengage the lock claw by lifting up the cover as shown in Fig 8.
    
    Fig 8: Disengaging Lock Claw By Lifting Up Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
  4. Disconnect the connector by hand.
  5. If the connector and the pipe are stuck, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out.
    NOTE: Do not use any tools.
    
    Fig 9: Pushing & Pulling Pipe To Disconnect
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
  7. To protect the disconnected pipe and connector from damage and contamination, cover it with plastic bag.
    
    Fig 10: Covering Fuel Hose Connector With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Observe these precautions when connecting the fuel tube connector (quick type A).
  1. Check that there is no damage or contamination in the connected part of the pipe.
  2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.
    
    Fig 11: Pushing Pipe Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After finishing the connection, try to pull apart the pipe and the connector to confirm that they are securely connected.
    
    Fig 12: Confirming That Pipe & Connector Are Securely Connected
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. w/ Fuel pipe clamp type:
    Install the fuel pipe clamp to the connector.
    
    Fig 13: Installing Fuel Pipe Clamp To Connector (W/Fuel Pipe Clamp Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. w/ Fuel hose connector cover type:
    Attach the lock claws to the connector by pushing down on the cover as shown in Fig 14.
    
    Fig 14: Attaching Lock Claws To Connector By Pushing Down On Cover (W/Fuel Hose Connector Cover Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Observe these precautions when disconnecting the fuel tube connector (quick type B).
  1. Check for dirt or mud on the pipe and around the connector before disconnecting them. Clean if necessary.
  2. Be sure to disconnect the connector by hand.
  3. When the connector and the pipe are stuck, push the tabs of the retainer and pull the connector to free to disconnect it and pull it out.
    
    Fig 15: Pushing Tabs Of Retainer & Pulling Connector To Free
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Do not use any tools.
  4. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
  5. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
    
    Fig 16: Covering Pipe & Connector With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Observe these precautions when connecting the fuel tube connector (quick type B).
  
  Fig 17: Observing Precautions When Connecting Tube Connector (Quick Type B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not reuse the retainer removed from the pipe.
  1. Connect the retainer to the pipe by hand.
    NOTE: Do not use any tools.
  2. Check is there is any damage or foreign objects on the connected part of the pipe.
  3. Match the axis of the connector with part of the pipe, and push in the connector until the connector makes a "click" sound. In the joint part is too tight to connect them, apply a little new engine oil on the tip of the pipe.
  4. After finishing the connection, check if the pipe and the connector are securely connected by pulling them.
  5. Check if there is any fuel leakage.
10. Observe the following precautions when handling the nylon tube.
  1. Do not turn the joint part of the nylon tube and the quick connector forcefully when connecting them.
  2. Do not twist the nylon tube.
  3. Do not remove the EPDM protector on the outside of the nylon tube.
  4. Do not connect them by bending the nylon tube.