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Precaution [11/2021 - ]

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WARNING:
  • Never perform work on fuel system components near any possible ignition sources.
    GTY657996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • Vaporized fuel could ignite, resulting in a serious accident.
  • Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
    GTY657995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
  • The fuel tank sub-assembly is very heavy. Be sure to follow the procedure described in the repair information, or the fuel tank sub-assembly may fall off the engine lifter.
    GTY563885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.
    GTY613008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. BEFORE WORKING ON FUEL SYSTEM 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.

      Refer to REMOVAL [11/2021 - ]

    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. When discharging fuel system pressure by disconnecting the EFI MAIN NO. 2 relay:
      1. Remove the No. 1 relay block cover.
      2. Remove the EFI-MAIN NO. 2 relay.
      3. Disconnect the fuel (engine room side) pump assembly connector.
        GTY1075300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Start the engine. After the engine has stopped on its own, turn the ignition switch off.
        NOTE:

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

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

        HINT: 

        DTC P0087-00 (Fuel Rail / System Pressure - Too Low) or P0171-00 (System Too Lean Bank 1) may be stored. Clear the DTCs before proceeding to the next step.

        Refer to DTC CHECK / CLEAR [11/2021 - 03/2023] , or refer to DTC CHECK / CLEAR [03/2023 - ]

      6. Disconnect the cable from the negative (-) battery terminal.

        Refer to REMOVAL [11/2021 - ]

      7. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank sub-assembly.
      8. Connect the fuel (engine room side) pump assembly connector.
      9. Install the EFI-MAIN NO. 2 relay.
      10. Install the No. 1 relay block cover.
  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 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. GTY996167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Open
        Pull

        Clamp Type A (EFI Fuel Pipe Clamp):

        Open the cover of the EFI fuel pipe clamp and remove the EFI fuel pipe clamp from the fuel tube connector.

      2. GTY754436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Clamp Type B (Fuel Pipe Clamp):

        Remove the fuel pipe clamp from the fuel tube connector.

      3. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
      4. While holding the retainer at the positions shown in the illustration, pull up the retainer to disengage the lock claws.
        GTY787203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Retainer Holding Position
        Pull out
      5. Pull up the retainer while holding it at the positions shown in the illustration and pull off the fuel tube connector.
        GTY876577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Nylon Tube
        Retainer Holding Position
        Pull out
        Pull off
      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:
        • 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, push the fuel tube connector onto the fuel pipe, then push in the retainer to secure the connection.
        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.

        GTY824760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Clamp Type A (EFI Fuel Pipe Clamp):

        Install the EFI fuel pipe clamp to the fuel tube connector and close the cover of the EFI fuel pipe clamp.

      4. Clamp Type B (Fuel Pipe Clamp):

        Install the fuel pipe clamp to the fuel tube connector.

      5. 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. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        GTY803483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        Pull out
        Pull off
      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:

        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).

      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 secure the connection.
        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.

        GTY825918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      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 2 claws of the retainer. Pull out the retainer and pull off the fuel tube connector.
        GTY994025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Claw
        Pull
        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 an O-ring that seals the pipe (fuel pipe).
      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.
    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 engage the 2 claws.
        GTY994063Courtesy 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

    8. Quick Type D:

      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. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        GTY789244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        Pull out
        Pull off
      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:

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

      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.
    9. Quick Type D:

      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.
        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.

        GTY798159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      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

    10. Quick Type E:

      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. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        GTY780935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        Pull out
        Pull off
      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:

        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).

      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.
    11. Quick Type E:

      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.
        NOTE:

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

        GTY794433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in

        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

  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.
    GTY1076000Courtesy 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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