From 08/2009

2GR-FE FUEL: FUEL SYSTEM: PRECAUTION

1. BEFORE WORKING ON FUEL SYSTEM

(a) When disconnecting a fuel line, fuel will splash. So observe the following precautions:

(1) Do not smoke or work near fire when handling the fuel system.

(2) Keep gasoline away from rubber or leather parts.

(3) Perform the Discharge Fuel System Pressure procedure below before disconnecting a fuel line to prevent gasoline from spilling out.

2. DISCHARGE FUEL SYSTEM PRESSURE

CAUTION:
* 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 shop rag or a piece of cloth to prevent fuel from spraying or coming out.
(a) For work associated with removal of the C/OPN relay:

(1) Remove the relay block cover.

(2) Remove the C/OPN relay.

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(3) Start the engine.

(4) After the engine stops, turn the engine switch off.

HINT
DTC P0171/25 (fuel problem) may be detected.

(5) Crank the engine again. Check that the engine does not start.

(6) Remove the fuel tank cap to discharge pressure from the fuel tank.

(7) Disconnect the cable from the negative (-) battery terminal.

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

(8) Install the C/OPN relay.

(b) Perform the following procedure to disconnect the fuel pump connector:

(1) Remove the rear No. 1 seat assembly (for LH side) Removal.

(2) Remove the rear door scuff plate LH Removal.

(3) Remove the rear door opening trim weatherstrip LH Removal.

(4) Remove the rear floor service hole cover.

(5) Disconnect the fuel pump connector.

(6) Start the engine.

(7) After the engine stops, turn the engine switch off.

HINT
DTC P0171/25 (fuel problem) may be detected.

(8) Crank the engine again. Check that the engine does not start.

(9) Remove the fuel tank cap to discharge pressure from the fuel tank.

(10) Disconnect the cable from the negative (-) battery terminal.

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

(11) Reconnect the fuel pump connector.

(12) Install the rear floor service hole cover.

(13) Install the front floor carpet with the clip.

(14) Install the rear door opening trim weatherstrip LH Installation.

(15) Install the rear door scuff plate LH Installation.

(16) Install the rear No. 1 seat assembly (for LH side) Installation.

3. FUEL LINE

(a) When disconnecting a high pressure fuel line, a large amount of gasoline will spill out, so perform the following procedure:

(1) Discharge fuel system pressure (Step 2).

(2) Disconnect the fuel pump tube.

(3) Drain the fuel that remains in the fuel pump tube.

(4) Cover the disconnected fuel pump tube with a plastic bag to prevent damage and contamination.

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(5) Put a container under the connectors.

(b) Perform the following procedure when disconnecting the fuel tube connector (quick type A):

(1) Remove the fuel pipe clamp.

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(2) Check whether there is any dirt in the pipe around the connector before disconnecting it and remove the dirt as necessary.

(3) Disconnect the connector from the pipe by hand.

NOTICE:
Be sure to disconnect the connector by hand.

(4) If the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.

NOTICE:
Be sure to disconnect the connector by hand.

(5) Check that there is no dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the surfaces if necessary.

(6) Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.

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(1) Check if there is any damage or foreign objects on the connecting parts of the pipes.

(2) Line up the 2 parts of the pipes to be connected, and push them together until the connector makes a "click" sound. 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.

(3) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.

(4) Inspect for fuel leaks Testing and Inspection.

(5) Install the fuel pipe clamp.

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(d) Perform the following procedure when disconnecting a fuel tube connector (quick type B):

(1) Before disconnecting the connector, clean off any dirt that may be present.

(2) Pinch the tabs of the fuel tube retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.

NOTICE:
Be sure to disconnect the connector by hand.

(3) If the connector and pipe are stuck, push and pull on the connector while holding the pipe by hand. Pull the 2 pipes apart to separate the connector.

NOTICE:
Be sure to disconnect the connector by hand.

(4) Check if there is any dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the sealing surfaces if necessary.

(5) Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.

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(e) Perform the following procedure when connecting the fuel tube connector (quick type B):

(1) Line up the 2 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.

(2) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.

(3) Inspect for fuel leaks Testing and Inspection.

(f) Observe the following precautions when handling a nylon tube:

CAUTION:
* Do not twist the connector part of the nylon tube or the quick connector when connecting them.
* Do not bend or twist the nylon tube.
* Do not remove the EPDM protector on the outside of the nylon tube.
* Do not pinch or kink the nylon tubes to prevent fuel leakage.
4. INJECTOR

(a) Install the injector to the delivery pipe and the lower intake manifold as shown in the illustration.

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NOTICE:
Before installing the injector, be sure to apply appropriate lubricant or gasoline where the delivery pipe or cylinder head contacts the injector O-rings.

(b) Observe the following precautions when removing and installing the fuel injectors:

(1) Never reuse an O-ring.

(2) When placing a new O-ring on the injector, do not damage the O-ring.

(3) Coat a new O-ring with spindle oil or gasoline before installing it.

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

5. FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

(a) 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.

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6. INSPECT FOR FUEL LEAK

(a) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs Testing and Inspection.