Fuel System Precaution

Before starting work on the fuel system, including inspections and repairs, disconnect the cable from the negative (-) battery terminal.

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

Keep gasoline away from rubber or leather parts.

Disconnect the fuel pump connector.

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

HINT:

DTC P0171/25 (system too lean) may be stored.

Crank the engine again and check that the engine does not start.

Loosen the fuel tank cap and discharge the pressure in the fuel tank completely.

Connect the fuel pump connector.

When disconnecting a high pressure fuel line, a large amount of gasoline will spill out. Follow these procedures.

1. Disconnect the fuel pump tube.
   

2. Drain any fuel remaining inside the fuel pump tube.
   

3. To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag.
   

4. Put a container under the connection.
   

Observe these precautions when removing and installing the injector.

1. Never reuse the O-ring.
   

2. When installing a new O-ring to the injector, do not damage it.
   

3. Coat new O-rings with spindle oil or gasoline before installing them. Do not use engine oil, gear oil or brake oil.
   

Install the injector to the delivery pipe and cylinder head as shown in the illustration.

NOTICE:

Before installing the injector, apply spindle oil or gasoline to the area where the delivery pipe contacts the O-ring of the injector.

Observe these precautions when disconnecting the fuel tube connector.

1. for Fuel Pipe Clamp Type:
   Remove the fuel pipe clamp from the fuel tube connector.
   

   Text in Illustration

   *1	Fuel Pipe Clamp





2. for Fuel Hose Connector Cover Type:
   Detach the lock claw by lifting up the cover as shown in the illustration.
   

   Text in Illustration

   *1	Fuel Hose Connector Cover

3. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
   





4. If the connector and the pipe are stuck together, pinch the connector, and then push and pull the pipe to disconnect the pipe and pull it out.
   

   Text in Illustration

   	Pinch
   	Pull

   NOTICE:

   
   
   1. Check for foreign matter 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.
      
   2. Do not use any tools to separate the pipe and connector.
      
   3. Do not forcefully bend or twist the nylon tube.
      
   4. Check for foreign matter on the pipe seal surface. Clean if necessary.
      
   5. Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
      
   6. If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
      

   Text in Illustration

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

5. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
   

6. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
   

Observe these precautions when connecting the fuel tube connector.

1. Check that there is no damage or contamination in the connected part of the pipe.
   





2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a little amount of fresh engine oil on the tip of the pipe.
   

   Text in Illustration

   Push





3. 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

4. for Fuel Pipe Clamp Type:
   Install the fuel pipe clamp to the fuel tube connector.
   

5. for Fuel Hose Connector Cover Type:
   Attach the lock claws to the connector by pushing down on the connector cover.
   

6. Check for any fuel leaks.
   

Check that there are no fuel leaks after performing maintenance anywhere on the fuel system (HILUX_TGN26 RM000000YL7040X.html).