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Precaution [09/2015 - 12/2017]

WARNING:
  • The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair information, or the fuel tank 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.
      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 [09/2015 - 12/2017]

    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 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. Remove the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 23 [09/2015 - 08/2016] , or refer to PROCEDURE - Step 23 [08/2016 - 12/2017]

      4. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
        GTY669000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. 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.

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

        HINT: 

        DTC P0087-00 (Fuel Rail / System Pressure - Too Low), P0171-00/P0174-00 (System Too Lean), P1603-00 (Engine Stall History), P1604-00 (Startability Malfunction) or P1605-00 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Refer to DTC CHECK / CLEAR [09/2015 - ]

      7. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      8. 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 [09/2015 - 08/2016] , or refer to INITIALIZATION [08/2016 - 12/2017]

      9. Connect the No. 6 engine wire connector and No. 7 engine wire connector.
      10. Install the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 40 [09/2015 - 08/2016] , or refer to PROCEDURE - Step 40 [08/2016 - 12/2017]

      11. Install the FUEL PMP relay.
      12. 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.
      2. Remove the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 23 [09/2015 - 08/2016] , or refer to PROCEDURE - Step 23 [08/2016 - 12/2017]

      3. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
        GTY669000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. 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.

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

        HINT: 

        DTC P0087-00 (Fuel Rail / System Pressure - Too Low), P0171-00/P0174-00 (System Too Lean), P1603-00 (Engine Stall History), P1604-00 (Startability Malfunction) or P1605-00 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Refer to DTC CHECK / CLEAR [09/2015 - ]

      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 [09/2015 - 08/2016] , or refer to INITIALIZATION [08/2016 - 12/2017]

      8. Connect the No. 6 engine wire connector and No. 7 engine wire connector.
      9. Install the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 40 [09/2015 - 08/2016] , or refer to PROCEDURE - Step 40 [08/2016 - 12/2017]

      10. Connect the fuel pump connector.
  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. Clamp Type:
        GTY684967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Remove the No. 2 fuel pipe clamp from the fuel tube connector.

      2. Cover Type:

        Pull off the fuel tube connector cover.

        GTY510333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuel Tube Connector Cover
        Pull off
      3. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
      4. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.
        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.

      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:
        • 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.
      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 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.
        GTY452003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Pull
      3. Clamp Type:

        Install the No. 2 fuel pipe clamp to the fuel tube connector.

      4. Cover Type:

        Push in the fuel tube connector cover.

      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. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        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.
        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.
        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.
        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. 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.
      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.
      GTY669542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for TMC Made
      *B for TMMC Made
      *a Tube
    • When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.
  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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