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 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 THE 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.
7. Reconnect the fuel pump connector.




b. 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 nut, and tighten the flare nut by hand.
2. Using SST, tighten the flare nut to specified torque.
SST 09023-38400

NOTE: Do not rotate the fuel pipe, when tightening the flare nut.

Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for using SST

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




c. 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 but never use engine, gear or brake oil.




d. Install the injector to the delivery pipe and cylinder head, as shown in the illustration.
e. Observe these precautions when disconnecting the fuel tube connector (quick type):




1. Disconnect the fuel pipe clamp from the connector.
2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.




3. Be sure to disconnect by hand.
4. When the connector and the pipe are stuck, pinch the retainer by hand, push and pull the connector to free the connection and pull it out. Do not use any tools at this time.
5. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.
6. Prevent the disconnected pipe and connector from being damaged and foreign objects mixing in objects by covering them with a vinyl bag.

f. Observe these precautions when connecting the fuel tube connector (quick type):




1. Do not reuse the retainer removed from the pipe.
2. Remove the retainer from the pipe by hand. Do not use any tools.
3. Check if there is any damage or foreign objects on the connected part of the pipe.




4. Match the axis of the connector with the axis of the pipe, and push in the connector until the retainer makes a "click" sound. In case that the connection is tight, apply a little amount of new engine oil onto 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. Install the fuel pipe clamp to the connector.
7. Check if there is any fuel leak.

g. Observe these precautions when disconnecting the fuel tube connector (metallic type):






HINT: The structure of the metallic connector is shown as above.

1. Check that there is any dirt like mud in the pipe and around the connector before disconnecting them and remove the dirt if any.




2. Assemble SST to the connection as shown in the illustration.
SST 09268-21010




3. Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector.




4. While holding the SST, pull the connector towards the SST to put the retainers on the SST chamfered parts.
5. Slide the SST and the connector together towards the fuel tube assembly.

h. Observe these precautions when connecting the fuel tube connector (metallic type):
1. Check that there is any damage or foreign objects in the connected part of the pipe.




2. Match the axis of the connector with the axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connection is tight, apply a little amount of fresh engine oil onto the tip of the pipe.




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

i. Observe these precautions when handling a nylon tube:
1. Pay attention not to turn the connected part of the nylon tube and quick connector with tube when connecting them.
2. Pay attention not to kink the nylon tube.
3. Do not remove the nylon tube.
4. Do not close the piping with the nylon tube by bending it.




j. 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.
- Connect the TOYOTA hand-held tester to the DLC3.
- Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON.
- Select the ACTIVE TEST mode on the TOYOTA hand-held tester.

NOTE: Do not start the engine.

- Please refer to the TOYOTA hand-held tester operator's manual for further details.

If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.

2. Check that there is no leak in any parts of the fuel system.
3. Turn the ignition switch OFF.
4. Disconnect the TOYOTA hand-held tester from the DLC3.