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Fuel System: Precaution: Precaution

  1. PRECAUTION 
    1. Before working on the fuel system, disconnect the cable from the negative battery terminal.
    2. Do not work on the fuel system near any open flames. Never smoke when working on this system.
    3. Keep rubber and leather parts away from gasoline.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • Perform the following procedure to prevent fuel from spilling out before removing any fuel system parts.
    • Even after discharging the fuel pressure, when disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.
    1. Remove the circuit opening relay from the engine room relay block.
    2. Start the engine.
    3. After the engine stops naturally, turn the ignition switch off.

      HINT: 

      DTC P0171 (system too lean (Bank 1)) or DTC P0174 (system too learn (Bank 2)) may be set.

    4. Crank the engine again and make sure that the engine does not start.
    5. Remove the fuel tank cap and discharge the pressure from the fuel tank.
    6. Install the circuit opening relay.
  3. INJECTOR 
    1. Observe the following precautions when removing and installing the fuel injector.
      Fig 1: Identifying Precautions When Removing And Installing Fuel Injectors
      GTY172146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a OK
      *b NG
      1. Do not reuse the O-ring and insulator.
      2. When placing a new O-ring onto the injector, do not damage the O-ring.
      3. Coat the new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil.
    2. Install the injector into the delivery pipe and lower intake manifold as shown in the illustration.
      Fig 2: Identifying Fuel Injector O-Ring
      GTY176197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-Ring
      NOTE:

      Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or lower intake manifold contacts the O-ring of the injector.

  4. FUEL SYSTEM 
    1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures.
      1. Discharge the fuel system pressure.
      2. Disconnect the fuel tank main tube. Refer to REMOVAL - Step 12 .
      3. Drain the fuel remaining inside the fuel tank main tube.
      4. Protect the contact surface by covering it with a plastic bag.
        Fig 3: Identifying High Pressure Fuel Line And Plastic Bag
        GTY179516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Plastic Bag
        NOTE:

        Do not damage the pipe or fuel tube connector, and prevent entry of foreign objects.

      5. Put a container under the connection.
    2. Observe the following precautions when disconnecting the fuel tube connector (Quick Type A).
      1. Fuel tube connector cover type:

        Disengage the lock claw by lifting up the cover, as shown in the illustration.

        Fig 4: Identifying Lock Claw
        GTY174984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Fuel Tube Connector Cover
        Up
      2. Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
        Fig 5: Identifying Retainer, Nylon Tube, Pipe, O-Rings And Fuel Tube Connector
        GTY179426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        *2 Nylon Tube
        *3 Pipe
        *4 O-Ring
        *5 Fuel Tube Connector
      3. Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the fuel tube from the fuel pipe.
        Fig 6: Identifying Fuel Tube Connector And Retainer
        GTY183807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        Pinch
        Pull Out
        NOTE:

        Do not use any tools.

      4. If the connector and pipe are stuck, pinch the retainer with your hand, and then push and pull the connector to disconnect them.
        Fig 7: Identifying Connector, Pipe And Retainer
        GTY181000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
        Push
        NOTE:

        Do not use any tools.

      5. Check the sealing surfaces of the disconnected parts, and clean them if necessary.
      6. Protect the contact surface by covering it with a plastic bag.
        Fig 8: Identifying Connector And Plastic Bag
        GTY189677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Plastic Bag
        NOTE:

        Do not damage the pipe or fuel tube connector, and prevent entry of foreign objects.

    3. Observe the following precautions when connecting the fuel tube connectors (Quick Type A).
      Fig 9: Identifying Fuel Tube Connector (Quick Type A)
      GTY168731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Push
      1. Check that there are no scratches or foreign objects on the connecting part.
      2. Line up the pipe and connector and push them together until a "click" sound is heard.

        HINT: 

        If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.

      3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
        Fig 10: Identifying Pipe And Connector
        GTY168714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
      4. Fuel tube connector cover type:

        Engage the lock claws to the connector by pushing down on the cover.

      5. Inspect for fuel leaks.
    4. Observe the following procedure when disconnecting the fuel tube connectors (Quick Type B).
      Fig 11: Identifying Fuel Tube Connectors (Quick Type B)
      GTY188139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nylon Tube
      *2 O-Ring
      *3 Retainer
      *4 Pipe
      1. Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      2. Disconnect them by hand.
        Fig 12: Identifying Fuel Tube Connectors (Quick Type B)
        GTY182476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Turn
        Pull
        NOTE:

        Do not use any tools.

      3. If the fuel tube connector and the pipe are stuck, push and pull on the fuel tube connector to release them. Pull the fuel tube connector out of the pipe carefully
        NOTE:

        Do not use any tools.

      4. Check the sealing surfaces of the disconnected parts, and clean them if necessary.
      5. Protect the contact surface by covering it with a plastic bag.
        NOTE:

        Do not damage the pipe or fuel tube connector, and prevent entry of foreign objects.

    5. Observe the following procedure when connecting the fuel tube connector (Quick Type B).
      Fig 13: Identifying Fuel Tube Connectors (Quick Type B)
      GTY182475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Push
      1. Check that there are no scratches or foreign objects on the connecting part.
      2. Line up the pipe and connector and push them together until a "click" sound is heard.

        HINT: 

        If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.

      3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
        Fig 14: Identifying Fuel Tube Connectors (Quick Type B)
        GTY182486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
      4. Inspect for fuel leaks.
    6. Observe the following procedure when disconnecting the fuel tube connectors (Quick Type C).
      Fig 15: Identifying Fuel Tube Connectors (Quick Type C)
      GTY173176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pipe
      *2 Retainer
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      1. Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      2. Pinch the tab on the retainer of the fuel tube connector to disengage the lock claws. Push it down as shown in the illustration.
        Fig 16: Identifying Fuel Connector Tube And Lock Claws
        GTY189988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        Push
        Down
        Pull
        NOTE:

        Do not use any tools.

      3. If the fuel tube connector and the pipe are stuck, push and pull on the fuel tube connector to release them. Pull the fuel tube connector out of the pipe carefully.
        Fig 17: Disconnecting Connector
        GTY104528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
        Push
        NOTE:

        Do not use any tools.

      4. Check the sealing surfaces of the disconnected parts, and clean them if necessary.
      5. Protect the contact surface by covering it with a plastic bag.
        Fig 18: Identifying Fuel Tube Connector And Plastic Bag
        GTY167229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Plastic Bag
        NOTE:

        Do not damage the pipe or fuel tube connector, and prevent entry of foreign objects.

    7. Observe the following procedure when connecting the fuel tube connector (Quick Type C).
      Fig 19: Identifying Fuel Tube Connectors (Quick Type C)
      GTY173653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      Up
      Push
      1. Check that there are no scratches or foreign objects on the connecting part.
      2. Line up the pipe and connector and push them together until a "click" sound is heard.

        HINT: 

        If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.

      3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
        Fig 20: Checking Connector Connection
        GTY145155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
    8. Observe these precautions when disconnecting the fuel tank breather tube connector:
      Fig 21: Identifying Fuel Tank Breather Tube Connector, Pipe, Nylon Tube And O-Ring
      GTY182429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Fuel Tank Breather Tube Connector
      *2 Pipe
      *3 Nylon Tube
      *4 O-Ring
      1. Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      2. Pinch the retainer and pull out the fuel tank breather tube connector with the fuel tank breather tube connector pushed to the pipe side to disconnect the fuel tank breather tube from the pipe.
        Fig 22: Identifying Fuel Tube Connectors (Quick Type C)
        GTY184186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Fuel Tank Breather Tube Connector
        *2 Pipe
        Push
        Pinch
        NOTE:

        Do not use any tools.

      3. If the connector and pipe are stuck, pinch the retainer with your hand, and then push and pull the connector to disconnect them.
        NOTE:

        Do not use any tools.

      4. Check the sealing surfaces of the disconnected parts, and clean them if necessary.
      5. Protect the contact surface by covering it with a plastic bag.
        NOTE:

        Do not damage the pipe or fuel tube connector, and prevent entry of foreign objects.

    9. Observe these precautions when connecting the fuel tank breather tube connector:
      Fig 23: Identifying Fuel Tank Breather Tube Connector
      GTY182017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Push
      1. Check that there are no scratches or foreign objects on the connecting part.
      2. Align the fuel tank breather tube connector with the pipe, then push in the fuel tank breather tube connector until the retainer makes a "click" sound to install the fuel tank breather tube to the pipe.
      3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
        Fig 24: Identifying Fuel Tank Breather Tube Connector
        GTY182018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
      4. Inspect for fuel leak.
  5. INSPECT FOR FUEL LEAK 
    1. Check that there is no fuel leakage after performing maintenance anywhere on the fuel system See step  1.
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