Fuel System Precaution

Before inspecting and repairing the fuel system, disconnect the cable from the negative battery terminal.

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

Keep gasoline away from rubber or leather parts.

Do not work near an open flame.

Keep gasoline away from rubber and leather parts.

Discharge the fuel pressure before disconnecting the fuel line to prevent gasoline from spilling out. Refer to the following procedure.

Remove the rear console box sub-assembly (RAV4_ACA30 RM000001RHJ00GX_01_0039.html).

Disconnect the fuel pump and sender gauge connector.

Start the engine. After the engine has stopped, turn the ignition switch off.

HINT:

If DTC P0171 (system too lean) is output, clear the DTC (RAV4_ACA30 RM000000PDK0BLX.html).

Check that the engine does not start.

Remove the fuel tank cap, and let the air out of the fuel tank.

Connect the fuel pump and sender gauge connector.

Install the rear console box sub-assembly (RAV4_ACA30 RM000001RHG00HX_01_0010.html).

When disconnecting a high-pressure fuel line, a large amount of gasoline will spray out. Perform the following procedure:

1. Discharge fuel system pressure.
   

2. Disconnect the fuel tube.
   

3. Drain the fuel remaining inside the fuel tube into a container.
   





4. To prevent damage and contamination, cover the disconnected pipe and connector with a plastic bag.
   

   Text in Illustration

   *1	Plastic Bag

Perform the following procedure when disconnecting a fuel delivery pipe (for Metallic Type):

HINT:

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

1. Check if there is any damage or foreign objects on the pipe connection.
   

   Text in Illustration

   *1	O-Ring
   *2	Retainer
   *3	Pipe
   *4	Nylon Tube
   *5	Fuel Tube Connector





2. Remove the No. 2 fuel pipe clamp.
   

   Text in Illustration

   *1	No. 2 Fuel Pipe Clamp

   NOTICE:

   Do not reuse the fuel pipe clamp.

3. Find the metallic connector of the fuel tube assembly.
   





4. Install SST to the connector as shown in the illustration.
   

   SST

   09268-21010
   





5. Turn SST, align the retainers inside the connector with SST chamfers and insert SST into the connector.
   

6. Slide SST and the connector together towards the fuel tube assembly.
   

Perform the following procedure when connecting a fuel tube connector (for Metallic Type):

1. Check if there is any damage or foreign objects on the pipe connection area.
   





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 the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe.
   

3. After connecting, check if the pipe and the connector are securely connected by pulling on them.
   





4. Install a new No. 2 fuel pipe clamp.
   

   Text in Illustration

   *1	No. 2 Fuel Pipe Clamp

5. Inspect for fuel leak.
   

Perform the following procedure when disconnecting a fuel tube connector (for Quick Type):

1. Remove the No. 1 fuel pipe clamp.
   

   Text in Illustration

   *1	No. 1 Fuel Pipe Clamp

2. Check that there is no dirt or other foreign objects on the pipe and contact surface before disconnecting them. Clean them if necessary.
   

3. Disconnect the connector from the pipe by hand.
   





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

5. Check that there is no dirt or other foreign objects on the contact surface of the disconnected pipe. Clean them if necessary.
   





6. Do not damage the disconnected pipe or connector, and prevent entry of foreign objects by covering them with plastic bags.
   

   Text in Illustration

   *1	Plastic Bag

Perform the following procedure when connecting a fuel tube connector (for Quick Type):

1. Check if there is any damage or foreign objects on the pipe connection.
   

2. Line up the two 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. Attach the lock claws and install the No. 1 fuel pipe clamp.
   

   Text in Illustration

   *1	No. 1 Fuel Pipe Clamp

5. Inspect for fuel leak.
   

Observe the following precautions when removing and installing the fuel injector.

1. Do not reuse an O-ring or insulator.
   

2. When placing a new O-ring onto the injector, do not damage the O-ring.
   

3. Coat a new O-ring with grease or gasoline before installing it. Do not use engine oil, gear oil or brake fluid.
   

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.

Make sure that there are no fuel leaks after performing maintenance on the fuel system.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON, and turn the intelligent tester main switch on.
   

   NOTICE:

   Do not start the engine.

3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
   

4. Check that there are no leaks from the fuel system.
   

5. Turn the ignition switch off.
   

6. Disconnect the intelligent tester from the DLC3.