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Precaution [11/2016 - ]

WARNING: This page is about a different variant/trim than selected.
  1. 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.
  2. 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. When discharging fuel system pressure by disconnecting the C/OPN relay:
      1. Remove the engine room relay block and junction block assembly cover.
      2. Remove the C/OPN relay.
      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 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 [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. Install the C/OPN relay.
      8. Install the engine room relay block and 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 [12/2013 - ]

      2. 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.

      3. 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 [11/2016 - ]

      4. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      5. 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 - ]

      6. Connect the fuel pump connector.

        Refer to INSTALLATION [12/2013 - ]

  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. 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.
        Fig 1: Claws Securing No. 2 Fuel Pipe Clamp
        GTY442191Courtesy 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.
        Fig 2: Installing SST To Connector
        GTY360819Courtesy 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.
        Fig 3: Aligning Retainers Inside Fuel Tube Connector
        GTY449360Courtesy 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 4: Slide SST (Fuel Hose Puller) And 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 the fuel pipe into the fuel tube connector 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.
        Fig 5: Aligning Fuel Tube Connector With Fuel Pipe
        GTY435046Courtesy 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. Engage the 2 claws to 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.

        Fig 6: Removing Fuel Pipe Clamp
        GTY318116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the claw and remove the No. 1 fuel pipe clamp.
      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 7: Removing Fuel Tube Connector Off Of Fuel Pipe
        GTY455059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        *e Nylon Tube
        Pinch
        Pull
        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).
        • Do not bend, twist, pinch or kink the nylon tube.
      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 engine oil to the tip of the fuel pipe and reinsert it.
        Fig 8: Aligning Fuel Tube Connector With 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. Engage the claw and install 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 9: Disengaging 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 10: 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.
    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 11: Connecting Fuel Tube To 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

    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 12: 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.
    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 gasoline to the tip of the fuel pipe and reinsert it.
        Fig 13: Connecting Fuel Tube To 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

    10. 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 14: Disengaging 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 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 15: 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:
      Fig 16: Nylon Tube Fuel Tube Connector
      GTY432429Courtesy 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 fuel tube connector part of the nylon tube 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 pinch or kink the nylon tubes to prevent fuel leaks.
  4. FUEL INJECTOR ASSEMBLY 
    1. Observe the following precautions when removing and installing the fuel injector assemblies:
      Fig 17: Observe Fuel Injector Precautions
      GTY441696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *2 Fuel Delivery Pipe
      *a Correct
      *b Incorrect
      1. Do not reuse the O-ring or injector vibration insulator.
      2. When placing a new O-ring onto the fuel injector assembly, do not damage the O-ring.
      3. Coat a new O-ring with gasoline or spindle oil before installing it.
        NOTE:

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

    2. Install the fuel injector assembly into the fuel delivery pipe and cylinder head sub-assembly as shown in the illustration.
      Fig 18: Fuel Injector Assembly
      GTY444301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Delivery Pipe
      *2 O-ring
      *3 Injector Vibration Insulator
      NOTE:

      Apply gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and fuel injector assembly before installing it.

  5. 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 19: Fuel Suction Tube With Pump And Gauge Assembly
      GTY443342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tube
    2. 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

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