Fuel System

PRECAUTION
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 terminal.

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 the following procedures:





(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on its own, turn off the ignition switch.





(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(7) Reconnect the fuel pump connector.
(b) When connecting the flare nut or union bolt on the high pressure pipe union, observe the following procedures:





(1) Union Bolt Type: Always use a new gasket.
(2) Union Bolt Type: Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand.





(5) Flare Nut Type:
Using SST, tighten the flare nut to the specified torque. SST 09631-22020

Torque: 30 N.m (310 kgf.cm, 22 ft.lbf)

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





(c) Observe the following 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.





(d) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
(e) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.





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

NOTICE: 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) Check that there are no leaks from any part of the fuel system.
(7) Turn the ignition switch OFF.
(8) Disconnect the TOYOTA hand-held tester from the DLC3.
(9) Start the engine.

NOTICE: Keep cranking the engine until the air is removed from the fuel line.

(10) After the engine starts, check again that there are no fuel leaks.