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Fuel System: Precaution

  1. BEFORE WORKING ON FUEL SYSTEM 
    1. Do not work near an open flame.
    2. Keep gasoline away from rubber and leather parts.
    3. Discharge the fuel pressure before disconnecting the fuel line to prevent gasoline from spilling out. Refer to the following procedure.
  2. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: 
    • The DISCHARGE FUEL SYSTEM PRESSURE procedures must be performed before disconnecting any part of the fuel system.
    • After performing the DISCHARGE FUEL SYSTEM PRESSURE procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray.
    1. Remove the rear seat cushion assembly. (See REMOVAL  )
    2. Remove the rear floor service hose cover.
      Fig 1: Identifying Rear Floor Service Hose Cover
      G05387467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector from the fuel pump assembly.
    4. Start the engine. After the engine stops naturally, turn the ignition switch OFF.

      HINT:

      DTC P0171 (system too lean) may be set.

    5. Start the engine again and make sure that engine does not start.
      Fig 2: Locating Connector At Fuel Pump Assembly
      G05387468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the fuel tank cap, and let the air out of the fuel tank.
    7. Connect the connector.
      Fig 3: Locating Connector
      G05387469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the rear floor service hole cover with new butyl tape.
    9. Install the rear seat cushion assembly. (See INSTALLATION  )
    Fig 4: Identifying Rear Floor Service Hole Cover With New Butyl Tape
    G05387470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. FUEL SYSTEM 
    1. When disconnecting the high-pressure fuel line, a large amount of gasoline will spray out. So take the following precautions:
      1. Discharge the fuel system pressure.
      2. Disconnect the fuel tube.
      3. Drain the fuel remaining inside the fuel pump tube into a container.
      4. Do not damage the disconnected pipe or connector, and prevent entry of foreign objects by covering them with plastic bags.
        Fig 5: Covering Connector With Plastic Bags
        G05387471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe the following precautions when removing and installing the fuel injector.
      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 grease or gasoline before installing it. Do not use engine, gear or brake oil.
        Fig 6: Identifying O-Ring Correct And Incorrect Position
        G05387472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the injector into the delivery pipe and cylinder head, as shown in the illustration. Apply grease or gasoline to the contact surfaces of the injector before installing the injector.
    4. Observe the following precautions when disconnecting the fuel delivery pipe (metallic type).
      Fig 7: Identifying Fuel Injector, Insulator, Fuel Delivery Pipe And O-Ring
      G05387473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The structure of the fuel tube connector is as shown in the illustration.

      1. Check if there is any damage or foreign objects on the connecting parts of the pipes.
      2. Remove the No. 2 fuel pipe clamp.
      3. Find the metallic connector of the fuel tube assembly.
      4. Assemble SST to the connection as shown in the illustration.

        SST 09268-21010 

      5. Turn SST, align the retainers inside the connector with the SST chamfered parts and insert SST into the connector.
      6. Slide SST and the connector together towards the fuel tube assembly.
        Fig 8: Checking Fuel Tube Connector
        G05387474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Observe the following precautions when connecting the fuel tube connector (metallic type).
      1. Check if there is any damage or foreign objects on the connecting 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 a small amount of clean engine oil to the tip of the pipe.
      3. After finishing the connection, check if the pipe and the connector are securely connected by pulling on them.
      4. Install a No. 2 fuel pipe clamp.
      5. Inspect for fuel leak.
        Fig 9: Checking Fuel Tube Connector (Metallic Type)
        G05387475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Observe the following precautions when disconnecting the fuel tube connectors (Quick Type A).
      1. Release the claw and remove the No. 1 fuel pipe clamp.
      2. Check that there is no dirt or other foreign objects on the pipe and around the connector before disconnecting them. Clean them if necessary.
        Fig 10: Identifying Fuel Pipe Clamp And Claw
        G05387476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Pinch the fuel tube connector, and then disconnect the fuel tube. Do not use any tools.
      4. Drain the fuel remaining inside the fuel tube.
        Fig 11: Pinching Fuel Tube Connector And Fuel Tube
        G05387477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnect part.
        Fig 12: Covering Fuel Tube And Fuel Pipe With Plastic Bag
        G05387478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Observe the following precautions when connecting the fuel tube connectors (Quick Type A).
      1. Check if there is any damage or foreign objects on the connecting parts of the pipes.
      2. Line up the two parts of the pipes to be connected, and push them together until the connector makes a "click" sound. 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 13: Checking Fuel Tube Connectors
        G05387479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Attach the lock claws and install the No. 1 fuel pipe clamp.
      5. Inspect for fuel leak.
    Fig 14: Identifying Fuel Pipe Clamp And Claw
    G05387480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT FOR FUEL LEAK 
    1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.
      1. Connect an intelligent tester or Techstream to the DLC3.
      2. Turn the ignition switch to ON.
        NOTE: Do not start the engine.
      3. Turn the tester ON.
      4. Select the following menu items:
        1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP/SPD / ON
        2. Techstream - Select: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump Speed / ON
      5. Check that there are no leaks from the fuel system.
      6. Turn the ignition switch to OFF.
      7. Disconnect the intelligent tester or Techstream from the DLC3.
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