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Precaution [10/2017 - 09/2020]

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  1. BEFORE WORKING ON FUEL SYSTEM 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
      NOTE:

      After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

      Refer to PRECAUTION [10/2017 - 09/2020]

    2. Do not smoke or work near fire when handling the fuel system.
    3. Keep fuel away from rubber or leather parts.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.
    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
    • Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.
    1. Remove the rear seat cushion assembly.

      Refer to PROCEDURE - Step 3

    2. Remove the rear seat cushion lock hook.

      Refer to PROCEDURE - Step 4

    3. Remove the V-bank cover sub-assembly.

      Refer to PROCEDURE - Step 3

    4. Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.
      Fig 1: Removing The Rear Floor Service Hole Cover
      GTY633953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    5. Disconnect the fuel pump connector.
      Fig 2: Fuel Pump Connection
      GTY804669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
      Fig 3: Locating Connectors
      GTY684069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Start the engine. After the engine has stopped on its own, turn the engine switch off.
      NOTE:

      Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

    8. Crank the engine again and make sure that the engine does not start.

      HINT: 

      DTC P008700 (Fuel Rail / System Pressure - Too Low), P017100/P017400 (System Too Lean), P160300 (Engine Stall History), P160400 (Startability Malfunction) or P160500 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

      Refer to DTC CHECK / CLEAR [10/2017 - ]

    9. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
    10. 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 [10/2017 - 09/2020]

    11. Connect the No. 6 engine wire connector and No. 7 engine wire connector.
    12. Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.
    13. Clean the installation surfaces of the rear floor service hole cover and vehicle body.
    14. Connect the fuel pump connector.
    15. Install the rear floor service hole cover with new butyl tape.
    16. Install the V-bank cover sub-assembly.

      Refer to PROCEDURE - Step 104

    17. Install the rear seat cushion lock hook.

      Refer to PROCEDURE - Step 8

    18. Install the rear seat cushion assembly.

      Refer to PROCEDURE - Step 9

  3. FUEL LINE 
    1. When disconnecting a high-pressure fuel line, a large amount of fuel will spray. Perform the following procedure:
      1. Discharge fuel system pressure.
      2. Disconnect the fuel tube.
      3. Drain the fuel remaining inside the fuel pump tube into a container.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Quick Type A:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Cover Type:

        Pull off the fuel tube connector cover.

        Fig 4: Fuel Tube Connector Cover
        GTY510333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuel Tube Connector Cover
        Pull off
      2. Clamp Type (Type A):
        Fig 5: Open No. 1 Fuel Pipe Clamp
        GTY834695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 No. 1 Fuel Pipe Clamp

        Disengage the claw to open the cover of the No. 1 fuel pipe clamp.

        NOTE:

        Do not remove the No. 1 fuel pipe clamp from the fuel tube connector.

      3. Clamp Type (Type B):
        Fig 6: Remove No. 1 Fuel Pipe Clamp
        GTY829045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 No. 1 Fuel Pipe Clamp

        Remove the No. 1 fuel pipe clamp from the fuel tube connector.

      4. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
      5. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.
        Fig 7: Releasing Fuel Line Connector Lock
        GTY631803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Nylon Tube
        *e Fuel Pipe
        Pinch
        Pull off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      6. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
        • Do not bend, twist, pinch or kink the nylon tube.
      7. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      8. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    3. Quick Type A:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.
      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
        Fig 8: Align The Fuel Tube Connector With The Fuel Pipe
        GTY452003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Pull
      3. Clamp Type (Type A):

        Engage the claw to close the cover of the No. 1 fuel pipe clamp.

      4. Clamp Type (Type B):

        Install the No. 1 fuel pipe clamp to the fuel tube connector.

      5. Cover Type:

        Push in the fuel tube connector cover.

      6. Inspect for fuel leaks.

        See step  1

    4. Quick Type B:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        Fig 9: Disengage The 2 Claws Of The Retainer
        GTY453543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Nylon Tube
        *d Fuel Tube Connector
        *e O-ring
        *f Claw
        Push
        Pull out
        Pull off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
        • Do not bend, twist, pinch or kink the nylon tube.
      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    5. Quick Type B:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to engage the 2 claws.
        Fig 10: Align The Fuel Tube Connector
        GTY450375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Claw
        Push
        Push in
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.

        See step  1

    6. Quick Type C:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the claw to open the cover of the fuel hose clamp.
        Fig 11: Open Fuel Hose Clamp
        GTY810921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pipe Clamp
      2. Remove the fuel hose clamp from the fuel tube connector.
      3. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        Fig 12: Retainer To Disengage The Lock Claws
        GTY453017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Pull out
        Pull off
      4. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        Fig 13: Push And Pull The Fuel Tube Connector To Release
        GTY436488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        NOTE:

        Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

      5. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      6. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    7. Quick Type C:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to secure the connection.
        Fig 14: Identifying Fuel Tube Connector With The Fuel Pipe
        GTY433856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Install the fuel hose clamp to the fuel tube connector.
      4. Engage the claw to close the cover of the fuel hose clamp.
      5. Inspect for fuel leaks.

        See step  1

    8. Observe the following precautions when handling a nylon tube:
      NOTE:
      • Do not twist the nylon tube of the fuel tube connector or fuel tube connector when connecting it.
      • Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.
      • Do not bend, twist, pinch or kink the nylon tube.
      Fig 15: Observe The Following Precautions
      GTY432431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector
  4. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    NOTE:
    • Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.
    • When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.
    Fig 16: Fuel Suction Tube With Pump And Gauge Assembly
    GTY792475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Tube
  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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