Fuel Pressure Release: Service and Repair

1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY

HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery.

Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery.

2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM

3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS




4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures:
1. Disconnect the fuel pump connector.
2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.




3. Put a container under the connection.
4. Slowly loosen the connection.
5. Disconnect the connection.
6. Plug the connection with a rubber plug.




b. When connecting the union bolt on the high pressure pipe union, observe these procedures:
1. Always use 2 new gaskets.
2. Tighten the union bolt by hand.
3. Tighten the union bolt to the specified torque.
Torque: 34.3 Nm (350 kg.cm, 25 ft.lb)




c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand.
2. Using SST, tighten the flare nut to the specified torque.
SST 09631-22020
Torque: 28 Nm (285 kg.cm, 21 ft.lb)

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




d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring.
2. When placing a new O-ring on the injector, take care not to damage it in any way.
3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil.




e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration.




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

1. Connect a TOYOTA hand-held tester to the DLC3.
2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON.

NOTE: Do not start the engine.

3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester.
4. Please refer to the TOYOTA hand-held tester operator's manual for further details.
5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.




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

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

7. Turn the ignition switch OFF.
8. Disconnect the TOYOTA hand-held tester from the DLC3.