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Precaution [06/2016 - ]

NOTE:

Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.

WARNING:
  • Do not smoke or be near an open flame when working on the fuel system.
  • Keep gasoline away from rubber or leather parts.
  • Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.
  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Refer to PRECAUTION [06/2016 - ] ).

  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.
    • Even after discharging the fuel pressure, place a piece of cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
    1. Disconnect the cable from the negative (-) battery terminal.
    2. Remove rear seat cushion assembly LH.
    3. Remove the No. 2 rear floor service hole cover.
      GTY692320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the fuel suction tube assembly with pump and gauge connector.
      GTY692321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the cable to the negative (-) battery terminal.
    6. Start the engine. After the engine has stopped on its own, turn the ignition switch off.

      HINT: 

      Some DTCs may be stored. Clear the DTCs before proceeding to the next step.

    7. Crank the engine again, then check that the engine does not start.
    8. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
    9. Connect the fuel suction tube assembly with pump and gauge connector.
    10. Install the No. 2 rear floor service hole cover.
    11. Install rear seat cushion assembly LH.
  3. FUEL SYSTEM 
    1. When disconnecting a fuel pressure line, a large amount of gasoline will spill out. Perform the following procedure:
      1. Discharge fuel system pressure.
      2. Put a container under the connection.
      3. Disconnect the fuel pump tube.
      4. Drain the fuel remaining inside the fuel pump tube into the container.
      5. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
    2. Observe these precautions when connecting the fuel tube connector (for metallic type).
      1. Attach SST to the fuel pipe.
        GTY686697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: SU003-03936 
      2. Insert SST in the fuel tube connector side, and remove the fuel tube from the fuel pipe.
        TEXT IN ILLUSTRATION

        *1 Retainer
        *2 O-Ring
        *3 Housing
        *4 Fuel Pipe
        Insert
      3. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    3. Observe these precautions when connecting the fuel tube connector (for metallic type).
      1. Check for damage or foreign matter on the connected part of the fuel pipe.
      2. Align the fuel tube connector axis with the fuel pipe axis, and push the fuel tube connector in until the retainer makes a clicking sound.
        GTY391861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Push
      3. After connecting the fuel tube connector, pull the fuel tube connector and pipe, and then push them to check that they are connected firmly.
        GTY385885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Be sure to always finish checking the fuel pipe connections by pushing.

        TEXT IN ILLUSTRATION

        Pull
        Push
      4. Inspect for fuel leaks (see step  1).
    4. Observe these precautions when disconnecting the fuel tube connector (for quick type A).
      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.
        GTY225980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        Push
        Down
        Pull

        HINT: 

        If the connector and pipe are stuck, pinch the fuel pipe by hand and push and pull the connector to disconnect it.

        GTY529252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        Pull
        Push
        NOTE:
        • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
          GTY386646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Do not use any tools to separate the pipe and connector.
        • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
        • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
        • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
        TEXT IN ILLUSTRATION

        *1 Pipe
        *2 Retainer
        *3 Nylon Tube
        *4 Connector
        *5 O-Ring
      3. Check for foreign matter on the seal surface of the disconnected pipe. Clean it if necessary.
      4. To protect the disconnected pipe and connector from damage and foreign matter, cover them with a plastic bag.
    5. Observe these precautions when connecting the fuel tube connector (for quick type A).
      1. Check for foreign matter on the pipe and around the connector before connecting it. Clean it if necessary.
      2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector, and then push up on the retainer.
        GTY263244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        Up
        Push
        NOTE:
        • Before connecting the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
          GTY257980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • After connecting the pipe and the connector, check that the pipe and connector are securely connected by trying to pull them apart.
        TEXT IN ILLUSTRATION

        Pull
      3. Inspect for fuel leaks (see step  1).
    6. Perform the following procedure when disconnecting a fuel tube connector (Quick Type B).
      GTY696340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Fuel Tube Connector
      *2 Fuel Pipe
      *3 Retainer
      Pinch
      Pull Out
      1. Check that there is no dirt or other foreign matter around the fuel tube connector before disconnecting it. Clean the joint if necessary.
      2. Pinch the retainer as illustrated, then pull out the fuel tube connector from the fuel pipe.
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      3. If the fuel tube connector and fuel pipe are stuck, pinch the fuel pipe, and then push and pull the fuel tube connector to release and disconnect the fuel tube connector.
        GTY705197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Check if there is any dirt or other foreign matter on the seal surface of the disconnected fuel pipe and clean it away as necessary.
      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    7. Perform the following procedure when connecting a fuel tube connector (Quick Type B).
      GTY350899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check for damage or foreign matter on the connected part of the fuel pipe.
      2. Align the fuel tube connector with the fuel pipe, and then push in the fuel tube connector until the retainer makes a "click" sound.

        HINT: 

        If the fuel pipe is difficult to push into the fuel tube connector, apply a light coat of engine oil to the tip of the fuel pipe and reinsert it.

      3. After finishing the connection, check that the fuel pipe and the fuel tube connector are securely connected by pulling on them.
        GTY350898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Inspect for fuel leaks (see step  1).
  4. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks anywhere on the fuel system after performing maintenance (See step  1).
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