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Precaution [08/2014 - ]

  1. PRECAUTIONS 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary battery terminal.
    2. Do not smoke or work near fire when handling the fuel system.
    3. Keep gasoline away from rubber or leather parts.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • Perform the following procedure to prevent fuel from spilling out 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 (Refer to Procedure - Step 3 ).
    2. Disengage the claw and remove the 2 rear seat cushion lock hooks (Refer to Procedure - Step 4 ).
    3. Remove the rear floor service hole cover.
      Fig 1: Location of fuel pump lid
      GTY536835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the fuel pump connector.
      Fig 2: Identifying Fuel Pump Connector
      GTY336472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Put the engine in inspection mode (Refer to INSPECTION MODE PROCEDURE [08/2014 - ] ).
    6. Start the engine.
    7. After the engine has stopped on its own, turn the power switch off.
    8. Crank the engine again and make sure that the engine does not start.

      HINT: 

      Some DTCs may be stored. Clear the DTCs before proceeding to the next step (Refer to DTC Check / Clear [08/2014 - ] ).

    9. Disconnect the cable from the negative (-) auxiliary battery terminal.
      NOTE:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to Initialization [08/2014 - 08/2015] Refer to Initialization [08/2015 - ] ).

    10. Connect the fuel pump connector.
    11. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
    12. Install the rear floor service hole cover with new butyl tape.
    13. Engage the claw to install the 2 new rear seat cushion lock hooks (Refer to Procedure - Step 3 ).
    14. Install the rear seat cushion assembly (Refer to Procedure - Step 4 ).
  3. FUEL LINE 
    1. When disconnecting a high-pressure fuel line, a large amount of gasoline will spray out. Perform the following procedure:
      1. Discharge the 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 pipe and connector with plastic bags to prevent damage and contamination.
    2. Perform the following procedure when disconnecting a fuel delivery pipe (metallic type):
      Fig 3: Fuel Tube Connector Component
      GTY534549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 O-ring
      *3 Nylon Tube
      *4 Housing
      *5 Pipe

      HINT: 

      The structure of a fuel tube connector is as shown in the illustration.

      1. Check if there is any damage or foreign matter on the pipe connections.
      2. Remove the No. 2 fuel pipe clamp.
        Fig 4: Removing The No. 2 Fuel Pipe Clamp
        GTY533084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B
        NOTE:

        Do not reuse the fuel pipe clamp (Type B).

      3. Assemble SST to the connector as shown in the illustration.
        Fig 5: Identifyimg Special Tool
        GTY530463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09268-21011 
      4. Turn SST, align the retainers inside the connector with the SST chamfers and insert SST into the connector.
        Fig 6: Connecting fuel pipe assembly
        GTY528618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer (4 places)
        *a Turn
        *b Push
      5. Slide SST and the connector together towards the fuel tube assembly.
    3. Perform the following procedure when connecting a fuel tube connector (metallic type):
      1. Check if there is any damage or foreign matter on the pipe connections.
      2. Match the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. If it is difficult to push the pipe into the connector, apply a small amount of clean engine oil to the tip of the pipe.
        Fig 7: Checking Damage Or Foreign Objects On The Pipe Connections
        GTY254655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Push
        *b Pull
      3. After connecting, check that the pipe and the connector are securely connected by pulling on them.
      4. Install the No. 2 fuel pipe clamp. (Type A)
        Fig 8: Installing No. 2 Fuel Pipe Clamp
        GTY525357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B
      5. Install a new No. 2 fuel pipe clamp. (Type B)
      6. Inspect for fuel leaks (Refer to  1).
    4. Perform the following procedure when disconnecting a fuel tube connector (quick type A):
      1. Release the claw and remove the No. 1 fuel pipe clamp.
        Fig 9: Fuel Pipe Clamp
        GTY528209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage the lock claws by raising the fuel hose connector cover as shown in the illustration.
        Fig 10: Raising Fuel Hose Connector Cover
        GTY529803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Fuel Hose Connector Cover
      3. Check that there is no dirt or other foreign matter on the pipe and contact surface before disconnecting them. Clean them if necessary.
      4. Disconnect the connector from the pipe by hand.
      5. If the connector and the pipe are stuck, push in and pull on the connector to release them. Pull the connector out of the pipe carefully.
        Fig 11: Pulling On Connector To Release
        GTY525824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        *2 O-ring
        *a Pinch
        *b Pull Out
      6. Check that there is no dirt or other foreign matter on the contact surface of the disconnected pipe. Clean them away if necessary.
      7. Cover the disconnected pipe and connector with plastic bags to prevent damage and contamination.
    5. Perform the following procedure when connecting a fuel tube connector (quick type A):
      1. Check if there is any damage or foreign matter on the pipe connections.
        Fig 12: Checking That Fuel Pipe Is Secure
        GTY258855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Push
        *b Pull
      2. Match the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. If it is difficult to push the pipe into the connector, apply a small amount of clean engine oil to the tip of the pipe.
      3. After connecting, check that the pipe and connector are securely connected by pulling on them.
      4. Engage the lock claws to the connector by pushing down on the fuel hose connector cover.
        Fig 13: Identifying Fuel Hose Connector Cover
        GTY535707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Fuel Hose Connector Cover
      5. Inspect for fuel leaks (Refer to  1).
      6. Engage the lock claw and install the No. 1 fuel pipe clamp.
        Fig 14: Fuel Pipe Clamp
        GTY528209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Perform the following procedure when disconnecting a fuel tube connector (quick type B):
      Fig 15: Disconnecting Fuel Tube Connector
      GTY527422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      1. Check that there is no damage or foreign matter on the part of the pipe that contacts the connector.
      2. Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe.

        HINT: 

        Be sure to disconnect it by hand.

      3. If the connector and pipe are stuck, pinch the fuel pipe by hand and push or pull the connector to disconnect it.
        Fig 16: Pinch Fuel Pipe By Hand, Push / Pull The Connector To Disconnect
        GTY529252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Check for foreign matter on the seal surface of the disconnected pipe. Clean it if necessary.
      5. Cover the disconnected pipe and connector with plastic bags to prevent damage and contamination.
    7. Perform the following procedure when connecting a fuel tube connector (quick type B):
      1. Line up the two parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.
        Fig 17: Connecting Fuel Tube Connector
        GTY101237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
      3. Inspect for fuel leaks (Refer to  1).
    8. Observe the following precautions when handling a nylon tube.
      1. Do not twist the connection part of the nylon tube and the quick connector when connecting them.
      2. Do not bend, kink, or twist the nylon tube.
      3. Do not remove the EPDM protector on the outside of the nylon tube.
      4. Do not close the piping by kinking the nylon tube.
  4. INJECTOR 
    1. Observe the following precautions when removing and installing a fuel injector:
      Fig 18: Removing/Installing Fuel Injector
      GTY333367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-ring
      *2 Delivery Pipe
      *a CORRECT
      *b INCORRECT
      1. Do not reuse the O-ring and insulator.
      2. When placing a new O-ring onto the injector, do not damage the new O-ring.
      3. Coat the new O-ring with grease or gasoline before installing it. Do not use engine oil, gear oil or brake fluid.
    2. Install the injector into the delivery pipe and cylinder head as shown in the illustration. Apply grease or gasoline to the contact surfaces of the injector before installing the injector.
      Fig 19: Identifying Delivery Pipe And Cylinder Head
      GTY233199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Delivery Pipe
      *2 O-ring
      3 Insulator
  5. FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube assembly with pump and gauge. Doing so will cause reassembly of the fuel suction tube assembly with pump and gauge to be impossible as the tube is welded to the plate.
      Fig 20: Identifying Fuel Suction Tube
      GTY327152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Tube
  6. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system (Refer to  1).
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