Fuel System

CAUTION:
1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.
2. Keep gasoline away from rubber or leather parts.

NOTE: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is disconnected.
Therefore, if necessary, read the diagnosis before disconnecting the negative
(-) terminal cable from the battery.

FUEL SYSTEM

CAUTION:





1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures:
(a) Put a container under the connection.
(b) Slowly loosen the connection.
(c) Disconnect the connection.
(d) Plug the connection with a rubber plug.
2. When connecting the flare nut or union bolt on the high pressure pipe union, observe these procedure:





Union bolt type:
(a) Always use a new gasket.
(b) Tighten the union bolt by hand.
(c) Tighten the bolt to the specified torque.
Torque: 29 Nm (300 kg.cm, 22 ft. lbs.)
Flare nut type:
(a) Apply a light coat of engine oil on the flare and tighten the flare nut by hand.
(b) Using Special Service Tool (SST) Power Steering Hose Nut 14 x 17 mm Wrench Set # 09631 - 22020 or equivalent, tighten the flare nut to the specified torque.
Torque: 31 Nm (315 kg.cm, 23 ft. lbs.)





NOTE: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).





3. Observe the following precautions when removing and installing the injectors.
(a) Never reuse the O-rings.
(b) When placing new O-rings on the injector, take care not to damage it in any way.
(c) Coat the new O-rings with spindle oil or gasoline before installing - never use engine, gear or brake oil.





4. Install the injector in the delivery pipe and cylinder head as shown in the illustration.
5. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.
(a) Remove the center upper panel on the instrument panel.





(b) Connect the TOYOTA hand-held tester or equivalent to the Data Link Connector (DLC)3.
(c) Turn the ignition switch ON and TOYOTA hand-held tester main switch ON.

CAUTION: Do not start the engine.

(d) Select the active test mode on the TOYOTA hand-held tester or equivalent.
(e) Please refer to the TOYOTA hand-held tester or equivalent operator's manual for further details.
(f) If you have no TOYOTA hand-held tester or equivalent, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector.





(g) Pinch the fuel return hose. The pressure in the high pressure line will rise to approximately 392 kPa (4 kg/cm sq., 57 psi). In this state, check that there are no leaks from any part of the fuel system.

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

(h) Turn the ignition switch OFF.
(i) Disconnect the TOYOTA hand-held tester or equivalent from the DLC3.
(j) Reinstall the center upper panel on the instrument panel.