Precaution (08/2010 - 08/2011): Precaution

WARNING:

Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
Do not smoke or be near an open flame when working on the fuel system.
Keep gasoline away from rubber and leather parts.

DISCHARGE FUEL SYSTEM PRESSURE
WARNING:
- Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
- After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
1. Remove the engine room side cover LH.
2. Remove the engine room relay block cover.
3. Remove the circuit opening relay (C/OPN).
4. Start the engine. After the engine has stopped on its own, turn the engine switch off.
  HINT:
  
  If DTC P0230 is output, clear the DTC. Refer to DTC CHECK / CLEAR .
5. Crank the engine, then check that the engine does not start.
6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
7. Disconnect the cable from the negative (-) battery terminal.
  NOTE:
  When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
8. Install the circuit opening relay (C/OPN).
9. Install the engine room relay block cover.
10. Install the engine room side cover LH.
FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures.
  1. Perform the "Discharge Fuel System Pressure" procedures above.
  2. Put a container under the connecting part of the pressure line.
    
    Fig 2: Covering Connection With Plastic Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Slowly loosen the connection.
  4. Disconnect the connection.
  5. Plug the connection with a rubber plug and cover it with a plastic bag.
2. Observe these precautions when installing the injectors:
  - Never reuse the O-ring.
  - When placing a new O-ring on the injector, do not damage it.
  - Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil.
3. Install the injector to the delivery pipe and cylinder head as shown in the illustration.
  
  Fig 3: Identifying Delivery Pipe, O-Ring, Injector And Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector.
4. Observe these precautions when disconnecting the fuel tube connector (for metallic type):
  1. Remove the No. 2 fuel pipe clamp.
    NOTE:
    Do not reuse the No. 2 fuel pipe clamp.
  2. Wipe off any dirt on the fuel tube connector.
  3. Hold the fuel tube connector and install SST.
    - SST: 09268-21011
  4. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.
  5. Insert SST into the fuel tube connector and hold it. Then push the fuel tube connector toward SST.
  6. Mount the retainer of the fuel tube connector onto the chamfered part of SST.
  7. Slide SST and the fuel tube connector together towards the fuel tube until they make a "click" sound, and then disconnect the fuel tube.
    HINT:
    
    The structure of a fuel tube connector is as shown in the illustration.
  8. Drain the fuel remaining inside the fuel tube.
  9. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected parts.
5. Observe these precautions when connecting the fuel tube connector (for metallic type):
  1. Check if there is any damage or foreign objects on the pipe connection area.
  2. Match the axis of the connector with the axis of the pipe, and push the pipe into the connector 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.
    
    Fig 6: Checking Fuel Tube Connector (Metallic Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After connecting, check if the pipe and the connector are securely connected by pulling on them.
  4. Install a new No. 2 fuel pipe clamp.
  5. Check that there is no fuel leakage.
6. Observe these precautions when disconnecting the fuel tube connector (for quick type A).
  1. for Fuel Pipe Clamp Type:
    Remove the fuel pipe clamp from the fuel tube connector.
  2. for Fuel Hose Connector Cover Type:
    Detach the lock claw by lifting up the cover, as shown in the illustration.
  3. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
  4. Pinch the connector and disconnect the connector and pipe.
    
    Fig 9: Disconnecting Connector And Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the connector and the pipe are stuck together, pinch the connector, then push and pull the pipe to disconnect the pipe and pull it out.
    
    NOTE:
    Do not use any tools in this procedure.
  5. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
  6. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
7. Observe these precautions when disconnecting the fuel tube connector (for quick type B).
  1. Check that there is no damage or foreign matter on the part of the pipe that contacts the connector.
  2. Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe.
    HINT:
    
    If the connector and pipe are stuck, pinch the fuel pipe by hand, and push and pull the connector to disconnect it.
  3. Check for foreign matter on the seal surface of the disconnected pipe. Clean it if necessary.
  4. To protect the disconnected pipe and connector from damage and foreign matter, cover it with a plastic bag.
8. Observe these precautions when connecting the fuel tube connector (for quick type B).
  1. Check for foreign matter on the pipe and around the connector before connecting it. Clean it if necessary.
  2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector, and push up on the retainer.
  3. After connecting the pipe and connector, try to pull them apart to confirm that they are securely connected.
9. Observe these precautions when connecting the fuel tube connector (for quick type A).
  
  Fig 16: Pushing Pipe Into Connector Until Connector Makes Click Sound
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Check that there is no damage or contamination in the connection part of the pipe.
  2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
  3. After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected.
    
    Fig 17: Pulling Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. for Fuel Hose Connector Cover Type:
    Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
    
    Fig 18: Identifying Fuel Hose Connector Cover Type
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. for Fuel Pipe Clamp Type:
    Install the fuel pipe clamp to the connector.
    
    Fig 19: Identifying Fuel Pipe Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Check that there is no fuel leakage.
CHECK FOR FUEL LEAK
1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See step 1.