Fuel Tank: Service and Repair

COMPONENTS FOR FUEL TANK REMOVAL AND INSTALLATION





Toyota does not provide written instructions for Fuel Tank removal. Refer to the illustration above and observe the following precautions and procedures.


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

HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery.

- Do not smoke or work near an open flame when working on the fuel system.
- Keep gasoline away from rubber or leather parts.


PROCEDURES




1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe these procedures:
(a) Put a container under the connection.
(b) Slowly loosen the connection.
(c) Disconnect the connection.
(d) Plug the connection with a rubber plug.





2. When connecting the flare nut or union bolt on the high pressure pipe union, observe these procedures:

Union Bolt Type:
(a) Always use a new gasket.
(b) Tighten the union bolt by hand.
(c) Tighten the union bolt to the specified torque.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

Flare Nut Type:
(a) Apply a light coat of engine oil to the flare and tighten the flare nut by hand.





(b) Using SST, tighten the flare nut to the specified torque. SST 09631-22020

Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)

HINT: Use a torque wrench with a fulcrum length of
30cm (11.81 in.).

3. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.





(a) Connect the TOYOTA hand-held tester to the DLC3.
(b) Turn ignition switch ON and TOYOTA hand-held tester main switch ON.

NOTICE: Do not start the engine

(c) Select the active test mode on the TOYOTA hand-held tester.
(d) Please refer to the TOYOTA hand-held tester operator's manual for further details.
(e) If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.





(f) Pinch the fuel return hose. The pressure in high pressure line will rise to approx. 400 kPa (4 kgf/sq. cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system.

NOTICE: Always pinch the hose. Avoid bending as it may cause to hose to crack.

(g) Turn the ignition switch to LOOK.
(h) Disconnect the TOYOTA hand-held tester from the DLC3.