Fuel System (2UZ-FE): Precaution

WARNING: This page is about a different car, the 2004 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.

PRECAUTION
1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.
2. Do not smoke or work near fire when working on the fuel system.
3. Keep gasoline away from rubber or leather parts.
WORK FOR PREVENT GASOLINE FROM SPILLING OUT
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 or piece of cloth over fittings to prevent fuel splashing on yourself or in the engine compartment when separating the fittings.
1. Remove the circuit opening relay from the engine room relay block.
2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
  HINT:
  
  There is a case that DTC P0171 (system too lean) is output.
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 (-) terminal cable from the battery.
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 the following procedures:
  1. Disconnect the fuel pump tube. (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
  2. Drain the fuel remained inside the fuel pump tube.
  3. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
  4. Place a container under the connection.
2. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe the following procedures:
  1. Always use new gaskets.
  2. Tighten the union bolt by hand.
    
    Fig 3: Identifying Gaskets
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using SST, tighten the union bolt to the specified torque.
    SST 09612-24014(09617-24011)
    
    Torque:
    
    33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST
    
    39 N.m (400 kgf.cm, 29 ft.lbf)
  HINT:
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
  
  Fig 4: Tightening Union Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Observe the following precautions when removing and installing the injectors:
  1. Never reuse the O-ring.
  2. When placing a new O-ring on the injector, do not damage the O-ring.
  3. Coat the new O-ring with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake fluid.
    
    Fig 5: Identifying Delivery Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the injector to the delivery pipe and lower intake manifold, as shown in the illustration.
  NOTE: Before installing the injector, apply spindle oil or gasoline where the delivery pipe or intake manifold contacts the O-ring of the injector.
  
  Fig 6: Installing Injector To Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Observe the following precautions when disconnecting the fuel tube connector (Quick type A):
  1. Remove the fuel pipe clamp No. 1.
    
    Fig 7: Removing Fuel Pipe Clamp No. 1 (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that there is no dirt on the pipe and around the connector before disconnecting them. Clean them if necessary.
  3. Disconnect them by hand.
  4. When the connector and the pipe are stuck, pinch the fuel pipe with your fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out of the pipe.
  5. Check that there is no dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary.
  6. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
    
    Fig 8: Disconnecting Connector (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Observe the following precautions when connecting the fuel tube connector (Quick Type A):
  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. In case that the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.
    
    Fig 9: Connecting Connector (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After finishing the connection, check if the pipe and the connector are securely connected by pulling them.
  4. Check for fuel leaks.
7. Observe the following precautions when disconnecting the fuel tube connector (Quick type B):
  1. Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
  2. Disconnect them by hand.
    
    Fig 10: Checking Pipe And Connector Connection By Pulling Them (Quick Type A)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. When the connector and the pipe are stuck, push and pull the connector. Disconnect and pull it out. Do not use any tool at this time.
  4. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary.
  5. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
    
    Fig 11: Disconnecting Connector (Quick Type B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Observe the following precautions when connecting the fuel tube connector (Quick type B):
  1. Match the axis of the connector with the axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connection is tight, apply a small amount of new engine oil to the tip of the pipe.
  2. After finishing the connection, check if the pipe and the connector are securely connected by pulling them.
    
    Fig 12: Connecting Connector (Quick Type B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Check for fuel leaks.
    
    Fig 13: Checking Pipe And The Connector Connection By Pulling Them (Quick Type B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Observe the following precautions when disconnecting the fuel tube connector (Quick type C):
  1. Pull the fuel hose connector cover up to release the lock.
    
    Fig 14: Releasing The Lock (Quick Type C)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that there is no dirt in the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
  3. Be sure to disconnect them by hand.
  4. When the connector and the pipe are stuck, pinch the fuel pipe between the hands, and push and pull the connector. Disconnect and pull it out. Do not use any tool at this time.
  5. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary.
  6. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
    
    Fig 15: Disconnecting Connector (Quick Type C)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Observe the following precautions when connecting the fuel tube connector (Quick Type C):
  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. In case that the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.
    
    Fig 16: Connecting Connector (Quick Type C)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After finishing the connection, check if the pipe and the connector are securely connected by pulling them.
    
    Fig 17: Checking Pipe And Connector Are Securely Connected By Pulling Them (Quick Type C)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Lock the fuel hose connector cover.
    HINT:
    
    If the fuel tube is not completely connected, the half connection prevention connector prevents the fuel hose connector cover from being locked.
  5. Check for fuel leaks.
    
    Fig 18: Locking Fuel Hose Connector Cover (Quick Type C)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Observe the following precautions when handling a nylon tube:
  CAUTION:
  - Do not twist the connection part of the nylon tube and the quick connector by force when connecting them.
  - Do not twist the nylon tube.
  - Do not remove the EPDM protector on the outside of the nylon tube.
  - Do not close the piping with the nylon tube by bending it.
CHECK FUEL LEAK
1. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance (See ON-VEHICLE INSPECTION ).