Fuel System

SFI SYSTEM

PRECAUTION

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

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 pressure fuel 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 a new gasket.
2. Tighten the union bolt by hand.
3. Tighten the union bolt to the specified torque.
Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf)




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 09023-38400
Torque: 24 N.m (245 kgf.cm, 18 ft.lbf)

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. Observe these precautions when disconnecting the fuel tube connector (quick type):
1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away.
2. Be sure to disconnect by hands.
3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away.




5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag.




g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe.
2. Must use hands to remove the retainer from the pipe.
3. Check that there is any damage or foreign objects on the connected part of the pipe.
4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe.




5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
6. Check that there is any fuel leakage.

h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them.
2. Pay attention not to kink the nylon tube.
3. Do not remove the EPDM protector from the outside of the nylon tube.
4. Must not close the piping with the nylon tube by bending it.




i. 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 ignition switch ON and 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 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.

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

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