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Fuel System: Precaution

  1. PRECAUTION 
    1. Before inspecting and repairing the fuel system, disconnect the negative (-) battery cable.
    2. Do not smoke or work near fire when handling the fuel system.
    3. Keep gasoline away from rubber or leather parts.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    NOTE:
    • 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 a piece of cloth over fittings to prevent fuel from splashing on yourself or in the engine compartment when separating the fittings.
    1. When using the intelligent tester:
      1. Connect the intelligent tester to the DLC3.
      2. Put the vehicle in the "inspection mode". (See REPAIR INSTRUCTION )
      3. Turn the ignition switch ON.
      4. Turn the tester to the ON position.
      5. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST.
      6. Perform the ACTIVE TEST by referring to the table below.
        INTELLIGENT TESTER SPECIFICATION

        Intelligent Tester Displays Test Details Control Ranges
        FUEL PUMP/SPD Activate fuel pump (C/OPN Relay) ON/OFF
      7. Turn the fuel pump (C/OPN relay) off.
      8. Turn the ignition switch off immediately after the engine comes to a "rough idle state".
      NOTE: The hybrid system has a complicated process from "out of gas" to "engine stall". Therefore, "rough idle" is regarded as "stop".

      HINT:

      DTCs P0171/25 and P0174/25 indicating LEAN errors may be detected.

    2. When not using the intelligent tester (using C/OPN RLY):
      1. Disconnect the relay block No.3.
      2. Remove the junction block cover No.2.
      3. Remove the C/OPN RLY.
      4. Put the vehicle in the "inspection mode". (See REPAIR INSTRUCTION )
      5. Start the engine.
      6. Turn the ignition switch off immediately after the engine comes to the "rough idle state".
        NOTE: The hybrid system has a complicated process from "out of gas" to "engine stall". Therefore, "rough idle" is regarded as "stop".

        HINT:

        DTCs P0171/25 and P0174/25 indicating LEAN errors may be detected.

      7. Disconnect the negative (-) battery terminal cable.
      8. Install the C/OPN RLY.
      Fig 1: Identifying C/OPN RLY
      G05200828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. FUEL SYSTEM 
    1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe the following procedures:
      1. Discharge the fuel system pressure. (step 2)
      2. Disconnect the fuel tube.
      3. Drain the fuel that remains inside the fuel tube.
      4. Cover the disconnected fuel tubes with a plastic bag to prevent damage and foreign objects from entering the fuel line.
      5. Place a tray under the vehicle or connecting part to catch any fuel that may spill.
      Fig 2: Covering Connector With Plastic Bag
      G05200829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe the following precautions when removing and installing fuel injectors:
      1. Never reuse the O-rings.
      2. When placing a new O-ring on the injector, do not damage the O-ring.
      3. Coat new O-rings with grease or gasoline before installation. Do not use engine oil, gear oil or brake fluid.
      Fig 3: Identifying Correct Way Of Fuel Injectors Installation
      G05200830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the injector with the delivery pipe to the cylinder head as shown in the illustration.
      NOTE: Before installing the injector, be sure to apply grease or gasoline where the delivery pipe or cylinder head contacts an O-ring of the injector.
      Fig 4: Identifying Injector Parts
      G05200831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Observe the following precautions when disconnecting the fuel tube connector (Quick Type A):
      1. Check for dirt in the pipe around the connector before disconnecting. Clean away the dirt as necessary.
      2. Be sure to disconnect the connectors by hand.
      3. When the connector and the pipe are stuck, pinch the fuel pipe with the fingers, and push and pull the connector. Disconnect and pull the connector out of the pipe. Do not use any tools.
      4. Check for dirt or other foreign objects on the surface of the seal on the disconnected pipe and clean as necessary.
      5. Do not damage the disconnected pipe or connector. Cover the disconnected pipe and connector to prevent intrusion of foreign objects.
      Fig 5: Disconnecting Fuel Tube Connector (Quick Type A)
      G05200832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Observe the following precautions when connecting the fuel tube connector (Quick Type A):
      1. Check for 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. If the connection is excessively tight, apply a small amount of fresh engine oil to the tip of the pipe.
        Fig 6: Connecting Fuel Tube Connector (Quick Type A)
        G05200833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.
      Fig 7: Connecting Fuel Tube Connector (Quick Type A)
      G05200834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Observe the following precautions when disconnecting the fuel tube connector (Quick Type B):
      1. Check for dirt in the pipe around the connector before disconnecting. Clean away the dirt as necessary.
      2. Be sure to disconnect the connectors by hand.
      3. Pinch the tabs of the retainer of the fuel tube connector to disengage the claws and push the retainer down as shown in the illustration.
      4. When the connector and the pipe are stuck, pinch the fuel pipe with the fingers, and push and pull the connector. Disconnect and pull it out of the pipe. Do not use any tools.
      5. Check for dirt or other foreign objects on the surface of the seal on the disconnected pipe and clean as necessary.
      6. Do not damage the disconnected pipe or connector. Cover the disconnected pipe and connector to prevent intrusion of foreign objects.
      Fig 8: Disconnecting Fuel Tube Connector (Quick Type B)
      G05200835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Observe the following precautions when connecting the fuel tube connector (Quick Type B):
      1. Check for 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 in the fuel tube connector until it comes into contact with the seat. Then push in the retainer until the claws lock. If the connection is excessively tight, apply a small amount of fresh engine oil to the tip of the pipe.
        Fig 9: Connecting Fuel Tube Connector (Quick Type B)
        G05200836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.
  4. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks anywhere on the fuel system after performing maintenance (See ON-VEHICLE INSPECTION ).
    Fig 10: Connecting Fuel Tube Connector - (Quick Type B)
    G05200837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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