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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 9 (Fuel System (2ZR-FAE) (Inspection) (Model Code: ZRE172)) >> Fuel System >> Precaution [08/2016 - ] >> Precaution [08/2016 - ]

Precaution [08/2016 - ]

WARNING: This page is about a different variant/trim than selected.
  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. PRECAUTIONS 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
    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.
    • Perform the following procedure to prevent fuel from spraying 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 piece of cloth to prevent fuel from spraying or coming out.
    1. Remove the rear seat cushion assembly.
    2. Remove the rear floor service hole cover.
      Fig 1: Locating Fuel Pump Assembly Connector
      GTY455065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel pump connector.
    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 P0171 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) and P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

      Refer to DTC CHECK / CLEAR [08/2013 - ]

    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 [08/2016 - 08/2017] Refer to INITIALIZATION [08/2017 - ]

    8. Connect the fuel pump connector.
    9. Install the rear floor service hole cover with new butyl tape.
    10. Install the rear seat cushion assembly.
  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 tube into a container.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Metallic Type:

      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.
        GTY722130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Claw
        NOTE:

        Do not reuse the No. 2 fuel pipe clamp.

      2. Install SST (fuel hose puller) to the fuel tube connector as shown in the illustration.
        GTY694995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09268-21011 
      3. Turn SST (fuel hose puller), align the retainers inside the fuel tube connector with the SST (fuel hose puller) chamfers and insert SST (fuel hose puller) into the fuel tube connector.
        GTY730911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer (4 places)
      4. Mount the retainer of the fuel tube connector onto the chamfered part of SST (fuel hose puller).
      5. Slide SST (fuel hose puller) and the fuel tube connector together until they make a "click" sound, and then disconnect the fuel tube sub-assembly.
        Fig 2: Slide SST (Fuel Hose Puller) And The Fuel Tube Connector Together
        GTY437099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Tube Sub-assembly
        *a Retainer
        *b O-ring
        *c Nylon Tube
        *d Fuel Tube Connector
        *e 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).
        • 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. Metallic Type:

      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.
        GTY703633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Pull
      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Install a new No. 2 fuel pipe clamp.
      4. Inspect for fuel leaks.

        See step  1

    4. 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. Open the cover of the fuel pipe clamp and remove the fuel pipe clamp from the fuel tube connector.
        Fig 3: Removing Fuel Pump Clamp
        GTY603066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Open
        Pull
      2. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
      3. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.
        Fig 4: Pinch The Retainer Of The Fuel Tube Connector
        GTY439249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        Pinch
        Pull off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      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.
        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).
      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.
    5. 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.
        Fig 5: Align The Fuel Tube Connector With The Fuel Pipe
        GTY452003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Pull
      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 No. 1 fuel pipe clamp to the fuel tube connector and close the cover of the No. 1 fuel pipe clamp.
      4. Inspect for fuel leaks.

        See step  1

    6. 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.
        Fig 6: Pull Out The Retainer To Disengage The Lock Claws
        GTY442913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        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.
        Fig 7: Push And Pull The Fuel Tube Connector
        GTY444634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        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).
      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 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 engine oil to the tip of the fuel pipe and reinsert it.
        Fig 8: Align The Fuel Tube Connector With The Fuel Pipe
        GTY442088Courtesy 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

    8. 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 9: Disengaging Claws Of Retainer
        GTY452531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        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.
        Fig 10: Push And Pull The Fuel Tube Connector
        GTY427899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuel Pipe
        *b Retainer
        *c Nylon Tube
        *d Fuel Tube Connector
        *e O-ring
        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.
    9. 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 engine oil to the tip of the fuel pipe and reinsert it.
        Fig 11: Align The Fuel Tube Connector With The Fuel Pipe
        GTY423699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        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

    10. Observe the following precautions when handling a nylon tube:
      Fig 12: 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
      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.
  5. FUEL INJECTOR ASSEMBLY 
    1. Observe the following precautions when removing and installing the fuel injector assemblies:
      Fig 13: Observe The Following Precautions
      GTY434227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *2 Fuel Delivery Pipe Sub-assembly
      *a Correct
      *b Incorrect
      1. Do not reuse the O-ring.
      2. When installing a new O-ring to the fuel injector assembly, do not damage the O-ring.
      3. Apply gasoline or spindle oil to a new O-ring before installing it.
        NOTE:

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

    2. Install the fuel injector assembly to the cylinder head sub-assembly as shown in the illustration.
      Fig 14: Install The Fuel Injector Assembly
      GTY443069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Delivery Pipe Sub-assembly
      *2 O-ring
      *3 Injector Vibration Insulator
      1. Do not reuse the injector vibration insulator.
  6. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. 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 15: Do Not Disconnect The Tube
      GTY451896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tube
    2. When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.
  7. 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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