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- BEFORE WORKING ON THE FUEL SYSTEM, DISCONNECT THE NEGATIVE (-) TERMINAL CABLE FROM THE 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.
- DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM
- KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
- MAINTENANCE PRECAUTIONS In event of engine misfire, these precautions should be taken. Check proper connection to battery terminals, etc. After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. When cleaning the engine compartment, be especially careful to protect the electrical system from water. Precautions when handling oxygen sensor. Do not allow oxygen sensor to drop or hit against an object. Do not allow the sensor to come into contact with water. If vehicle is Equipped with Mobile Radio System (HAM, CB, etc.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section.
- AIR INDUCTION SYSTEM Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of turn. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of turn.
- ELECTRONIC CONTROL SYSTEM Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch to LOCK or disconnecting the negative (-) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (-) terminal cable from the battery. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (-) cables. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. Be careful during troubleshooting as there are numerous transistor circuit, and even slight terminal contact can cause further troubles. Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care should be taken when pulling out and inserting wiring connectors. Release the lock and pull out the connector, pulling on the connectors. Fully insert the connector and check that it is locked. Use SST for inspection or test of the injector or its wiring connector. SST 09842-30080
- FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. Disconnect the fuel pump connector. Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. Disconnect the fuel tube (See «REMOVAL»(ref-206126-S34540656692006062000000) ). Drain the fuel remained inside the fuel tube. Prevent the disconnected fuel tube from damaging and mixing foreign objects by covering them with a vinyl bag. Put a container under the connection. Observe these precautions when removing and installing the injector. Never reuse the O-ring. When placing a new O-ring on the injector, take care not to damage it in any way. Coat a new O-ring with spindle oil or gasoline before installing never use engine, gear or brake oil. Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before in installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or a cylinder head touches on O-ring of the injector. Observe these precautions when disconnecting the fuel delivery pipe. The structure of the metallic connector is shown as left. Remove the fuel pipe clamp. Get the metallic connector of the fuel tube assembly, pull it out towards the rear and hold it as it is. Assemble SST to the connection as shown. SST 09268-21010 Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector. Hold SST as it at step 4, push the connector towards SST to put the retainers on SST chamfered parts. Slide SST and the connector together towards the fuel tube assembly.
- Observe these precautions when disconnecting the fuel tube connector (quick type). Remove the fuel pipe clamp. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away. Be sure to disconnect with hands. When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
- Observe these precautions when connecting the fuel tube connector (quick type). Do not reuse the retainer removed from the pipe. Must use hands without using tools when to remove the retainer from the pipe. Check if there is any damage or foreign objects on the connected part of the pipe. Match the axis of the connector with axis of the pipe, and push in the connector until retainer makes a "click" sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. Install the fuel pipe clamp. Check if there is any fuel leakage.
- Observer these precautions when handling nylon tube. Pay attention not to turn the connected part of the nylon tube and the quick connector with force when connecting them. Pay attention not to kink the nylon tube. Do not remove the nylon tube. Must not close the piping with the nylon tube by bending it.
- Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
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- Connect the TOYOTA hand-held tester to the DLC3.
- Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON.
- Select the active test mode on the TOYOTA hand held tester.
- Please refer to the TOYOTA hand-held tester operators 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. (See «FUEL PUMP»(ref-206126-S06072678032006062000000) )
- Check that there are no leaks from any part of the fuel system.
- Turn the ignition switch to LOCK.
- Disconnect the TOYOTA hand-held tester from the DLC3.
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- CHECK FUEL PUMP OPERATION Connect the TOYOTA hand-held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. Select the active test mode on the TOYOTA hand-held tester. Please refer to the TOYOTA hand-held tester operators manual for further details. If you have no TOYOTA hand-held tester, connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that there is pressure in the fuel inlet pipe from the fuel line. HINT: If there is fuel pressure, you will hear the sound if fuel following. If there is no pressure, check these parts, Fusible link, Fuses, EFI Main relay, Fuel pump, ECM, and Witting connector. Turn the ignition switch to LOCK. Disconnect the TOYOTA hand-held tester from the DLC3.
- CHECK FUEL PRESSURE Check the battery positive voltage is above 12 V. Disconnect the negative (-) terminal cable from the battery. Purchase the new fuel tube and take out the fuel tub connector from its pipe. Part No.: 1ZZ-FE: 23901-22100 2ZZ-GE: 23271-88600 Remove the fuel pipe clamp. Disconnect the fuel tube (fuel tube connector) from the fuel pipe. CAUTION: Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. As there is retained pressure in the fuel pipe line, prevent if from splashing inside the engine comportment. Install SST (pressure gauge) as shown in the illustration by using SST and fuel tube connector. SST 09268-41047 (95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) Wipe off any splattered gasoline. Reconnect the negative (-) terminal cable to the battery. Connect the TOYOTA hand-held tester to the DLC3. If you have no TOYOTA hand-held tester, connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Measure the fuel pressure. Fuel pressure: 301 - 347 kPa (3.1 - 3.5 kgf/cm 2 , 44 - 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the Fuel hoses and connections, Fuel pump, Fuel filter, and Fuel pressure regulator. Disconnect the TOYOTA hand-held tester from the DLC3. Start the engine. Measure the fuel pressure at idle. Fuel Pressure: 301 - 347 kPa (3.1 - 3.5 kgf/cm 2 , 44 - 50 psi) Stop the engine. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel Pressure: 147 kPa (1.5 kgf/cm 2 , 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. After checking fuel pressure, disconnect the negative (- terminal cable from the battery and carefully, remove the SST and fuel tube connector to prevent gasoline from splashing. SST 09268-41047 (95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) Reconnect the fuel tube (fuel tube connector). CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. Install the fuel pipe clamp. Reconnect the negative (-) terminal cable to the battery. Check for fuel leakage.
- REMOVE REAR SEAT CUSHION
- REMOVE FLOOR SERVICE HOLE COVER
- DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
- INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 ohm at 20°C (68°F) If the resistance is not as specified, replace the fuel pump.
- INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 4 of the connector and the negative (-) terminal 5. Check that the pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil burning out. Keep fuel pump as far away from the battery as possible. Always do the switching at the battery side. If operation is not as specified, replace the fuel pump or lead wire.
- RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
- REINSTALL FLOOR SERVICE HOLE COVER
- REINSTALL REAR SEAT CUSHION
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INSPECT CAMSHAFT OIL CONTROL VALVE OPERATION
Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, and check the movement of the valve.
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If operation is not as specified, replace the valve.
See also:
• REMOVAL