Fuel System: Precaution: Precaution

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.
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.
  
  Fig 1: Identifying Circuit Opening Relay In Engine Room Relay Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Circuit Opening Relay
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 lean (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.

INJECTOR

Observe the following precautions when removing and installing the fuel injector.

Fig 2: Precautions - Removing/Installing Fuel Injectors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	O-Ring
*2	Delivery Pipe
*a	Correct
*b	Incorrect

Do not reuse the O-ring and insulator.
When placing a new O-ring onto the injector, do not damage the O-ring.
Coat the new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil.

Install the injector into the delivery pipe and lower intake manifold as shown in the illustration.

Fig 3: Identifying Injector Components

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Delivery Pipe
*2	O-Ring
*3	Injector
*4	Insulator
*5	Intake Manifold

NOTE:

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

FUEL SYSTEM

When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe these procedures.

Discharge the fuel system pressure.
Remove the charcoal canister protector. Refer to REMOVAL - Step 1 .
Disconnect the fuel tank main tube. Refer to REMOVAL - Step 3 .
Drain the fuel remaining inside the fuel tank main tube.

Protect the contact surface by covering it with a plastic bag.

Fig 4: Identifying High Pressure Fuel Line And Plastic Bag

Courtesy 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.

Put a container under the connection.

Observe the following precautions when disconnecting the fuel tube connector.

EFI fuel pipe clamp type A:

Remove the EFI fuel pipe clamp from the tube connector.

Fig 5: Identifying EFI Fuel Pipe Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	EFI Fuel Pipe Clamp

EFI fuel pipe clamp type B:

Disengage the claw and remove the EFI fuel pipe clamp from the tube connector.

Fig 6: Identifying Fuel Pipe Clamp (Type B)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	EFI Fuel Pipe Clamp
*2	Claw

Fuel tube connector cover type:

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

Fig 7: Identifying Lock Claw

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Fuel Tube Connector Cover
	Up

Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.

Fig 8: Identifying Retainer, Nylon Tube, Pipe, O-Rings And Fuel Tube Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Retainer
*2	Nylon Tube
*3	Pipe
*4	O-Ring
*5	Fuel Tube Connector

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 9: Identifying Fuel Tube Connector And Retainer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Retainer
	Pinch
	Pull Out

NOTE:

Do not use any tools.

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

Fig 10: Identifying Connector, Pipe And Retainer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

	Pull
	Push

NOTE:

Do not use any tools.

Check the sealing surfaces of the disconnected parts, and clean them if necessary.

Protect the contact surface by covering it with a plastic bag.

Fig 11: Identifying Connector And Plastic Bag

Courtesy 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.

Observe the following precautions when connecting the fuel tube connectors.

Fig 12: Precautions - Installing/Removing Fuel Tube Connectors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

Push

Check that there are no scratches or foreign objects on the connecting part.
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.

After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.

Fig 13: Securing Connector & Pipe

TEXT IN ILLUSTRATION

Pull

Fuel tube connector cover type:
Engage the lock claws to the connector by pushing down on the cover.
EFI fuel pipe clamp type A:
Install the EFI fuel pipe clamp to the tube connector.
EFI fuel pipe clamp type B:
Engage the claw and install the EFI fuel pipe clamp to the tube connector.
Inspect for fuel leaks.

Observe these precautions when disconnecting the charcoal canister outlet tube connector:

Fig 14: Identifying Fuel Tank Breather Tube Connector, Pipe, Nylon Tube And O-Ring

TEXT IN ILLUSTRATION

*1	Fuel Tank Breather Tube Connector
*2	Pipe
*3	Nylon Tube
*4	O-Ring

Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.

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 15: Identifying Fuel Tube Connectors (Quick Type C)

TEXT IN ILLUSTRATION

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

NOTE:

Do not use any tools.

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.
Check the sealing surfaces of the disconnected parts, and clean them if necessary.
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.

Observe these precautions when connecting the charcoal canister outlet tube connector:

Fig 16: Identifying Fuel Tank Breather Tube Connector

TEXT IN ILLUSTRATION

Push

Check that there are no scratches or foreign objects on the connecting part.
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.

After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.

Fig 17: Identifying Fuel Tank Breather Tube Connector

TEXT IN ILLUSTRATION

Pull

Inspect for fuel leak.

INSPECT FOR FUEL LEAK
1. Check that there is no fuel leakage after performing maintenance anywhere on the fuel system. See step 1.