LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2014 >> Highlander XLE, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 42 (Fuel System (2GR-FKS) (Inspection) (Except Hybrid)) >> Fuel System >> Precaution [11/2016 - ] >> Precaution [11/2016 - ]

Precaution [11/2016 - ]

WARNING: This page is about a different car, the 2019 Toyota Highlander, 2018 Toyota Highlander, and 2017 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. IGNITION SWITCH EXPRESSIONS 
    1. The type of ignition switch used on this model differs depending on the specifications of the vehicle. The expressions listed in the table below are used in this section.
      Expression Ignition Switch (Position) Engine Switch (Condition)
      Ignition Switch off LOCK Off (Lock)
      Ignition Switch ACC ACC On (ACC)
      Ignition Switch ON ON On (IG)
      Engine Start START On (Start)
  2. 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 ignition 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 [11/2016 - ]

    2. Do not smoke or work near fire when handling the fuel system.
    3. Keep fuel away from rubber or leather parts.
  3. 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 FUEL PMP relay:
      1. Remove the No. 1 engine room relay block and No. 1 junction block assembly cover.
      2. Remove the FUEL PMP relay.
      3. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
        Fig 1: No. 6 & No. 7 Engine Wire Connector Location
        GTY726993Courtesy 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 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 [11/2016 - ]

      6. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      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 [11/2016 - ]

      8. Connect the No. 6 engine wire connector and No. 7 engine wire connector.
      9. Install the FUEL PMP relay.
      10. Install the No. 1 engine room relay block and No. 1 junction block assembly cover.
    2. When discharging fuel system pressure by disconnecting the fuel pump connector:
      1. Disconnect the fuel pump connector.

        Refer to REMOVAL [11/2016 - ]

      2. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
        Fig 2: No. 6 & No. 7 Engine Wire Connector Location
        GTY726993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. 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.

      4. 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 [11/2016 - ]

      5. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      6. 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 [11/2016 - ]

      7. Connect the No. 6 engine wire connector and No. 7 engine wire connector.
      8. Connect the fuel pump connector.

        Refer to INSTALLATION [11/2016 - ]

  4. 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. Disengage the 2 claws to remove the No. 2 fuel pipe clamp.
        Fig 3: Fuel Pipe Clamp Claws Location
        GTY762901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A Fuel Pipe Camp Type A
        *B Fuel Pipe Camp Type B
      2. Remove the No. 1 fuel pipe clamp from the fuel tube connector.
        Fig 4: Removing Fuel Pipe Clamp
        GTY768559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A Fuel Pipe Camp Type A
        *B Fuel Pipe Camp Type B
      3. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
      4. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        Fig 5: Disengaging Fuel Tube Retainer
        GTY714359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Nylon Tube
        *e Fuel Pipe
        Pull out
        Pull off
      5. 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.
      6. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      7. 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. 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.
        Fig 6: Fuel Tube Connector
        GTY728620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      2. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Install the No. 1 fuel pipe clamp to the fuel tube connector.
      4. Fuel Pipe Clamp Type A:

        Engage the 2 claws to install the No. 2 fuel pipe clamp.

      5. Fuel Pipe Clamp Type B:

        Align the protrusions of the No. 2 fuel pipe clamp with the notches of the No. 1 fuel pipe clamp, and engage the 2 claws to install the No. 2 fuel pipe clamp.

        Fig 7: Fuel Pipe Clamp
        GTY764941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion
        *b Notch
      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 8: Disengaging Claws Of Fuel Tube 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, 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.
        Fig 9: Aligning Fuel Tube Connector
        GTY450375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Claw
        Push
        Push in
      2. Connect the fuel lines and push in the retainer to engage the 2 claws. 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 disconnect the fuel tube connector from the fuel pipe.
        Fig 10: Releasing Fuel Line Connector Lock
        GTY638353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e 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 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, 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.
        Fig 11: Connecting Fuel Pipe
        GTY662653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Claw
        Push
        Push in
      2. Connect the fuel lines and push in the retainer to engage the 2 claws. 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.
        Fig 12: Disengaging Retainer Lock Claws
        GTY453017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        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.
        Fig 13: Push And Pull 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).

      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, 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 engine oil to the tip of the fuel pipe and reinsert it.
        Fig 14: Connecting Fuel Tube And Fuel Pipe
        GTY433856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      2. Connect the fuel lines and push in the retainer. 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.
        Fig 15: Disengaging Retainer Lock Claws
        GTY738985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        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).
        • 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.
    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, 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 engine oil to the tip of the fuel pipe and reinsert it.
        Fig 16: Aligning Fuel Tube Connector With Fuel Pipe
        GTY695829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      2. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.

        See step  1

    12. 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 17: Fuel Tube Construction
      GTY432431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector
  5. 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.
      Fig 18: Identifying Fuel Suction Tube
      GTY621925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tube
    • When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.
  6. 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

scientia non olet · About LEMON Manuals