Fuel System: Precaution

PRECAUTIONS
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 naked flames. Never smoke during the work.
3. Keep rubber and leather parts away from gasoline.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
- Before removing any fuel system parts, take precautions to prevent gasoline spillage.
- As some pressure remains in the fuel line even after taking precautions to prevent gasoline spillage, use a shop rag or piece of cloth to prevent gasoline splashes when disconnecting the fuel line.
1. Remove the rear seat cushion (for Hatchback) (See REMOVAL ).
2. Remove the rear seat assembly (for Hatchback) (See REMOVAL ).
3. Remove the rear seat cushion (for Sedan) (See REMOVAL ).
4. Remove the rear floor service hole cover.
5. Disconnect the connector from the fuel pump assembly.
  
  Fig 1: Locating Fuel Pump Assembly Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Start the engine. After the engine stops naturally, turn the ignition switch OFF.
  HINT:
  
  DTC P0171 may be set.
7. Crank the engine again and make sure that the engine does not start.
8. Remove the fuel tank cap and discharge the pressure.
9. Disconnect the cable from the negative battery terminal.
10. Connect the connector of the fuel pump assembly.
FUEL SYSTEM
1. When disconnecting the high-pressure fuel line, a large amount of gasoline will splash. So take the following precautions.
  1. Discharge the fuel system pressure.
  2. Disconnect the fuel tube.
  3. Drain the fuel remaining inside the fuel pump tube.
  4. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign matter.
    
    Fig 2: Covering Disconnected Fuel Tube Connector & Pipe With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Observe the following precautions when removing and installing the fuel injector.
  1. Do not reuse the O-ring.
  2. When placing a new O-ring onto the injector, do not damage the O-ring.
  3. Coat the new O-ring with grease or gasoline before installing it. Do not use engine, gear or brake oil.
    
    Fig 3: Locating O-Ring Onto Injector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the injector into the delivery pipe and cylinder head. Apply grease or gasoline oil to the contact surfaces of the delivery pipe and injector before installing the injector.
  
  Fig 4: Identifying Delivery Pipe, O-Ring & Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Observe these precautions when disconnecting the fuel tube connector.
  1. Remove the fuel pipe clamp No.1.
  2. Check whether there is any dirt in the pipe around the connector before disconnecting it and remove the dirt as necessary.
    
    Fig 5: Locating Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If the connector and pipe are stuck, pinch the retainer with your hand, then push and pull the connector to disconnect them. Do not use any tools.
  4. Check the sealing surface of the pipe for dirt and mud. If dirty, wipe it with a shop rag or piece of cloth.
    
    Fig 6: Pulling Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign matter.
    
    Fig 7: Covering Disconnected Fuel Tube Connector & Pipe With Vinyl Bag
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Observe the following precautions when connecting the fuel tube connector.
  1. Check that there is no damage or foreign matter on the part of the pipe that comes into contact with the connector.
  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 too tight, apply a small amount of fresh engine oil to the tip of the pipe.
    
    Fig 8: Pushing Pipe Into Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After connecting the pipe and connector, try to pull them apart to confirm that they are securely connected.
  4. Attach the lock claws to the connector by pushing down on the cover.
    
    Fig 9: Pulling Pipe From Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR FUEL LEAKAGE
1. Check that there is no fuel leakage after performing maintenance anywhere on the fuel system (See ON-VEHICLE INSPECTION ).