Fuel Delivery and Air Induction: Service Precautions
2GR-FXE FUEL: FUEL SYSTEM: PRECAUTION
1. IGNITION SWITCH EXPRESSION
HINT
The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section.
2. BEFORE WORKING ON FUEL SYSTEM
(a) When disconnecting a fuel line, fuel will splash. Therefore, observe the following precautions:
(1) Do not smoke or work near fire when handling the fuel system.
(2) Keep gasoline away from rubber or leather parts.
(3) Perform the Discharge Fuel System Pressure procedure below before disconnecting a fuel line to prevent gasoline from spilling out.
3. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
* Perform the following procedure to prevent fuel from spilling out before removing any fuel system parts.
* Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a cloth to prevent fuel from spraying or coming out.
(a) Connect the Techstream to the DLC3.
(b) Remove the relay block cover.
(c) Remove the C/OPN relay.
(d) Put the engine in inspection mode Component Tests and General Diagnostics.
(e) Start the engine.
(f) After the engine stops, turn the ignition switch off.
HINT
Some DTCs may be stored. Clear the DTCs before proceeding to the next step.
(g) Crank the engine again. Check that the engine does not start.
(h) Remove the fuel tank cap to discharge pressure from the fuel tank.
(i) Install the C/OPN relay.
4. FUEL LINE
(a) When disconnecting a high pressure fuel line, a large amount of gasoline will spill out, so perform the following procedure:
(1) Discharge fuel system pressure.
(2) Disconnect the fuel pump tube.
(3) Drain the fuel that remains in the fuel pump tube.
(4) Cover the disconnected fuel pump tube with a plastic bag to prevent damage and contamination.
(5) Put a container under the connectors.
(b) Perform the following procedure when disconnecting a fuel tube connector (Quick Type A):
(1) Remove the fuel pipe clamp.
Text in Illustration
(2) Check whether there is any dirt on the pipe around the connector before disconnecting it and remove the dirt as necessary.
(3) Disconnect the connector from the pipe by hand.
Text in Illustration
NOTICE:
* Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
* Do not use any tools to separate the pipe and connector.
* Do not forcefully bend or twist the nylon tube.
* Check for foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
* If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
HINT
If the connector and the pipe are stuck, push and pull the connector to release it. Pull the connector off of the pipe carefully.
(4) Check that there is no dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the surfaces if necessary.
(5) Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
(c) Perform the following procedure when connecting a fuel tube connector (Quick Type A):
(1) Check if there is any damage or foreign objects on the connecting parts of the pipes.
(2) Line up the 2 parts of the pipes to be connected and push them together until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.
Text in Illustration
(3) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
(4) Inspect for fuel leaks Fuel System.
(5) Install the fuel pipe clamp.
(d) Perform the following procedure when disconnecting a fuel tube connector (Quick Type B):
(1) Before disconnecting the connector, clean off any dirt that may be present.
(2) Pinch the tabs of the fuel tube retainer to detach the 2 claws. Push the retainer down as shown in the illustration.
Text in Illustration
NOTICE:
* Be sure to disconnect the connector by hand.
* Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
* Do not use any tools to separate the pipe and connector.
* Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
* Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
* Do not forcibly bend, twist or turn the nylon tube.
* Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
* If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
Text in Illustration
HINT
If the connector and pipe are stuck, push and pull on the connector while holding the pipe by hand. Pull the 2 pipes apart to disconnect the connector.
Text in Illustration
(3) Check if there is any dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the sealing surfaces if necessary.
(4) Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
(e) Perform the following procedure when connecting a fuel tube connector (Quick Type B):
(1) Line up the 2 parts of the pipes to be connected and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.
Text in Illustration
(2) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.
(3) Inspect for fuel leaks Fuel System.
(f) Perform the following procedure when disconnecting a fuel tube connector (Quick Type C):
Text in Illustration
(1) Check if there is any dirt on the pipe around the connector before disconnecting it and clean the dirt away as necessary.
(2) Pinch the retainer as illustrated, and then pull the fuel tube connector off of the pipe.
NOTICE:
Be sure to disconnect the connector by hand.
HINT
If the fuel connector and pipe are stuck, pinch the pipe, and then push and pull the fuel tube connector to release and disconnect the fuel tube connector.
Text in Illustration
(3) Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean them away as necessary.
(4) Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
(g) Perform the following procedure when connecting a fuel tube connector (Quick Type C):
Text in Illustration
(1) Check for damage or foreign objects in the connecting part of the pipe.
(2) Align the fuel tube connector with the pipe, and then push in the fuel tube connector until the retainer makes a "click" sound.
HINT
If they are connected too tightly, apply a light coat of engine oil to the tip of the pipe, and then connect the fuel tube connector.
(3) After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.
Text in Illustration
(4) Inspect for fuel leaks Fuel System.
(h) Observe the following precautions when handling a nylon tube:
CAUTION:
* Do not twist the connecting part of the nylon tube or the quick connector when connecting them.
* Do not bend or twist the nylon tube.
* Do not remove the EPDM protector on the outside of the nylon tube.
* Do not pinch or kink the nylon tubes to prevent fuel leakage.
5. INJECTOR
(a) Install an injector to the delivery pipe and the lower intake manifold as shown in the illustration.
Text in Illustration
NOTICE:
Before installing the injector, be sure to apply appropriate lubricant or gasoline where the delivery pipe or cylinder head contacts the injector O-rings.
(b) Observe the following precautions when removing and installing the fuel injectors:
Text in Illustration
(1) Never reuse an O-ring.
(2) When placing a new O-ring on the injector, do not damage the O-ring.
(3) Coat a new O-ring with spindle oil or gasoline before installing it.
NOTICE:
Do not use engine oil, gear oil or brake fluid.
6. INSPECT FOR FUEL LEAK
(a) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs Fuel System.