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Fuel System: Precaution: Precaution

  1. BEFORE WORKING ON FUEL SYSTEM 
    1. When disconnecting a fuel line, fuel will splash. So observe the following precautions:
      1. Do not smoke or work near fire when handling the fuel system.
      2. Keep gasoline away from rubber or leather parts.
      3. Perform the Discharge Fuel System Pressure procedure below before disconnecting a fuel line to prevent gasoline from spilling out.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • Perform the following procedure to prevent fuel from spilling out before removing any fuel system parts.
    • Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out.
    1. Connect the Techstream to the DLC3.
    2. Remove the relay block cover.
    3. Remove the C/OPN relay.
      Fig 1: C/OPN Relay & Relay Block Cover
      GTY357038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 C/OPN
    4. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE .
    5. Start the engine.
    6. After the engine stops, turn the power switch off.

      HINT: 

      Some DTCs may be stored. Clear the DTCs before proceeding to the next step.

    7. Crank the engine again. Check that the engine does not start.
    8. Remove the fuel tank cap to discharge pressure from the fuel tank.
    9. Install the C/OPN relay.
  3. FUEL LINE 
    1. When disconnecting a high pressure fuel line, a large amount of gasoline will spill out, so perform the following procedure:
      1. Discharge fuel system pressure (Step 2).
      2. Disconnect the fuel pump tube.
      3. Drain the fuel that remains in the fuel pump tube.
      4. Cover the disconnected fuel pump tube with a plastic bag to prevent damage and contamination.
        Fig 2: Covering Disconnected Fuel Pump Tube With Plastic Bag
        GTY224254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Plastic Bag
      5. Put a container under the connectors.
    2. Perform the following procedure when disconnecting a fuel tube connector (Quick Type A):
      1. Remove the fuel pipe clamp.
        Fig 3: Identifying Fuel Pipe Clamp
        GTY303454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 1 Fuel Pipe Clamp
        *2 No. 2 Fuel Pipe Clamp
        *3 Connector Cover
      2. Check whether there is any dirt in the pipe around the connector before disconnecting it and remove the dirt as necessary.
      3. Disconnect the connector from the pipe by hand.
        Fig 4: Disconnecting Connector From Pipe
        GTY359917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Be sure to disconnect the connector by hand.

      4. If the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.
        NOTE:

        Be sure to disconnect the connector by hand.

      5. Check that there is no dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the surfaces if necessary.
      6. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
        Fig 5: Covering Disconnected Pipe And Connector With Plastic Bag
        GTY227704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Plastic Bag
    3. Perform the following procedure when connecting a fuel tube connector (Quick Type A):
      Fig 6: Checking Connector Connection
      GTY101695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check if there is any damage or foreign objects on the connecting parts of the pipes.
      2. Line up the 2 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.
      4. Inspect for fuel leaks See step  1.
      5. Install the fuel pipe clamp.
        Fig 7: No. 1 Fuel Pipe Clamp, No. 2 Fuel Pipe Clamp & Checker
        GTY350911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 1 Fuel Pipe Clamp
        *2 No. 2 Fuel Pipe Clamp
        *3 Connector Cover
    4. Perform the following procedure when disconnecting a fuel tube connector (Quick Type B):
      Fig 8: Pinching Tabs Of Fuel Tube Retainer
      GTY104951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Before disconnecting the connector, clean off any dirt that may be present.
      2. Pinch the tabs of the fuel tube retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.
        NOTE:

        Be sure to disconnect the connector by hand.

      3. If the connector and pipe are stuck, push and pull on the connector while holding the pipe by hand. Pull the 2 pipes apart to separate the connector.
        Fig 9: Disconnecting Connector
        GTY104528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Be sure to disconnect the connector by hand.

      4. Check if there is any dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the sealing surfaces if necessary.
      5. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
        Fig 10: Covering Disconnected Pipe And Connector With Plastic Bag
        GTY211178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Plastic Bag
    5. Perform the following procedure when connecting a fuel tube connector (Quick Type B):
      Fig 11: Connecting Fuel Tube Connector
      GTY101237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Line up the 2 parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. 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.
      2. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
      3. Inspect for fuel leaks See step  1.
    6. Perform the following procedure when disconnecting a fuel tube connector (Quick Type C):
      Fig 12: Checking That Pipe And Connector Are Securely Connected By Pulling On Them
      GTY301575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      1. Check if there is any dirt in the pipe around the connector before disconnecting them and clean the dirt away as necessary.
      2. Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe.
        NOTE:

        Be sure to disconnect the connector by hand.

      3. If the fuel connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector.
        Fig 13: Pinch The Pipe, Then Push And Pull The Fuel Tube Connector
        GTY356058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away as necessary.
      5. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
        Fig 14: Cover The Disconnected Pipe And Connector With A Plastic Bag
        GTY355469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Plastic Bag
    7. Perform the following procedure when connecting a fuel tube connector (Quick Type C):
      Fig 15: Connecting A Fuel Tube Connector (Quick Type C)
      GTY350899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check for damage or foreign objects in the connected part of the pipe.
      2. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound.

        HINT: 

        If they are connected too tightly, apply a light coat of engine oil to the tip of the pipe, then install the fuel tube connector.

      3. After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.
        Fig 16: Fuel Tube Connector
        GTY350898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Inspect for fuel leaks See step  1.
    8. Observe the following precautions when handling a nylon tube:
      WARNING:
      • Do not twist the connector part of the nylon tube or the quick connector when connecting them.
      • Do not bend or twist the nylon tube.
      • Do not remove the EPDM protector on the outside of the nylon tube.
      • Do not pinch or kink the nylon tubes to prevent fuel leakage.
  4. INJECTOR 
    1. Install a injector to the delivery pipe and the lower intake manifold as shown in the illustration.
      Fig 17: Identifying Delivery Pipe, O-Ring, Injector, Insulator And Intake Manifold
      GTY251160Courtesy 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, be sure to apply appropriate lubricant or gasoline where the delivery pipe or cylinder head contacts the injector O-rings.

    2. Observe the following precautions when removing and installing the fuel injectors:
      Fig 18: Identifying Injector O-Ring
      GTY147294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Never reuse an O-ring.
      2. When placing a new O-ring on the injector, do not damage the O-ring.
      3. Coat a new O-ring with spindle oil or gasoline before installing it.
        NOTE:

        Do not use engine oil, gear oil or brake fluid.

  5. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs See step  1.
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