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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Fuel System (2GR-FKS) - Inspection >> Fuel System >> Precaution [12/2019 - 10/2022] >> Precaution [12/2019 - 10/2022]

Precaution [12/2019 - 10/2022]

WARNING:
  • Never perform work on fuel system components near any possible ignition sources.
    GTY657996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • Vaporized fuel could ignite, resulting in a serious accident.
  • Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
    GTY657995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
  • The fuel tank sub-assembly is very heavy. Be sure to follow the procedure described in the repair information, or the fuel tank sub-assembly may fall off the engine lifter.
    GTY563885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.
    GTY613008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. BEFORE WORKING ON FUEL SYSTEM 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
      NOTE:

      After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

      Refer to INITIALIZATION [12/2019 - 09/2020] , or refer to INITIALIZATION [09/2020 - 10/2021] , or refer to INITIALIZATION [10/2021 - 10/2022]

    2. Do not smoke or work near fire when handling the fuel system.
    3. Keep fuel away from rubber or leather parts.
  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.
    • Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.
    1. When discharging fuel system pressure by disconnecting the FUEL PMP relay:
      1. Remove the No. 1 relay block cover.
      2. Remove the FUEL PMP relay.
      3. Remove the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 23 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 23 [09/2020 - 10/2022]

      4. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
        GTY726993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Start the engine. After the engine has stopped on its own, turn the ignition switch off.
        NOTE:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

      6. Crank the engine again and make sure that the engine does not start.

        HINT: 

        DTC P0087-00 (Fuel Rail / System Pressure - Too Low), P0171-00/P0174-00 (System Too Lean Bank 1/System Too Lean Bank 2), P1603-00 (Engine Stall History), P1604-00 (Startability Malfunction) or P1605-00 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Refer to DTC CHECK / CLEAR [12/2019 - 10/2022]

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

        Refer to PROCEDURE - Step 1

        NOTE:

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

        Refer to INITIALIZATION [12/2019 - 09/2020] , or refer to INITIALIZATION [09/2020 - 10/2021] , or refer to INITIALIZATION [10/2021 - 10/2022]

      8. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank sub-assembly.
      9. Connect the No. 6 engine wire connector and No. 7 engine wire connector.
      10. Install the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 52 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 52 [09/2020 - 10/2022]

      11. Install the FUEL PMP relay.
      12. Install the No. 1 relay block cover.
    2. When discharging fuel system pressure by disconnecting the fuel pump connector:
      1. Remove the rear floor service hole cover.

        Refer to REMOVAL [12/2019 - 10/2022]

      2. GTY887150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Disconnect the fuel pump connector.

      3. Remove the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 23 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 23 [09/2020 - 10/2022]

      4. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
        GTY726993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Start the engine. After the engine has stopped on its own, turn the ignition switch off.
        NOTE:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

      6. Crank the engine again and make sure that the engine does not start.

        HINT: 

        DTC P0087-00 (Fuel Rail / System Pressure - Too Low), P0171-00/P0174-00 (System Too Lean Bank 1/System Too Lean Bank 2), P1603-00 (Engine Stall History), P1604-00 (Startability Malfunction) or P1605-00 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Refer to DTC CHECK / CLEAR [12/2019 - 10/2022]

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

        Refer to PROCEDURE - Step 1

        NOTE:

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

        Refer to INITIALIZATION [12/2019 - 09/2020] , or refer to INITIALIZATION [09/2020 - 10/2021] , or refer to INITIALIZATION [10/2021 - 10/2022]

      8. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank sub-assembly.
      9. Connect the No. 6 engine wire connector and No. 7 engine wire connector.
      10. Install the V-bank cover sub-assembly.

        Refer to PROCEDURE - Step 52 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 52 [09/2020 - 10/2022]

      11. Connect the fuel pump connector.
      12. Install the rear floor service hole cover.

        Refer to INSTALLATION [12/2019 - 10/2022]

  3. FUEL LINE 
    1. When disconnecting a high-pressure fuel line, a large amount of fuel will spray. 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. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Quick Type A:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the 2 claws to remove the No. 2 fuel pipe clamp.
        GTY842723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. GTY927182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Remove the No. 1 fuel pipe clamp from the fuel tube connector.

      3. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
      4. While holding the retainer at the positions shown in the illustration, pull up the retainer to disengage the lock claws.
        GTY787203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Retainer Holding Position
        Pull out
      5. Pull up the retainer while holding it at the positions shown in the illustration and pull off the fuel tube connector.
        GTY876577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Nylon Tube
        Retainer Holding Position
        Pull out
        Pull off
      6. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
        • Do not bend, twist, pinch or kink the nylon tube.
      7. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      8. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    3. Quick Type A:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to secure the connection.
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

        GTY824760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Install the No. 1 fuel pipe clamp to the fuel tube connector.
      4. Align the protrusions of the No. 2 fuel pipe clamp with the notches of the No. 1 fuel pipe clamp, and engage the 2 claws to install the No. 2 fuel pipe clamp.
        GTY764941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion
        *b Notch
      5. Inspect for fuel leaks.

        See step  1

    4. Quick Type B:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        GTY806337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Claw
        Push
        Pull out
        Pull off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).
      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    5. Quick Type B:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to engage the 2 claws.
        GTY809469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Claw
        Push
        Push in
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.

        See step  1

    6. Quick Type C:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        GTY803483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        Pull out
        Pull off
      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:

        Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    7. Quick Type C:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to secure the connection.
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

        GTY825918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.

        See step  1

    8. Quick Type D:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        GTY944800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        Pull out
        Pull off
      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:

        Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    9. Quick Type D:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to secure the connection.
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        GTY857375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.

        See step  1

    10. Observe the following precautions when handling a nylon tube:
      NOTE:
      • Do not twist the nylon tube of the fuel tube connector or fuel tube connector when connecting it.
      • Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.
      • Do not bend, twist, pinch or kink the nylon tube.
      GTY432431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector
  4. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    NOTE:

    Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.

    GTY934688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Tube
  5. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.

      See step  1

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