SFI System (5VZ-FE): Precaution

HINT:

Any DTC 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.

BEFORE WORKING ON FUEL SYSTEM DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM 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
1. In the event of engine misfire, these precautions should be taken.
  1. Check proper connection to battery terminals, etc.
  2. After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely.
  3. When cleaning the engine compartment, be especially careful to protect the electrical system from water.
2. Precautions when handling the oxygen sensor.
  1. Do not allow oxygen sensor to drop or hit against an object.
  2. 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 appropriate article.
AIR INDUCTION SYSTEM
1. Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune.
2. 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 tune.
ELECTRONIC CONTROL SYSTEM
1. Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF 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.
2. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (-) cables.
3. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM.
4. Be careful during troubleshooting as there are numerous transistor circuits, and even slight terminal contact can cause further troubles.
5. Do not open the ECM cover.
6. When inspecting in rainy weather, take care to prevent an intrusion of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors.
7. Parts should be replaced as an assembly.
8. Care should be taken when pulling out and inserting wiring connectors.
  1. Release the lock and pull out the connector, pulling on the connectors.
  2. Fully insert the connector and check that it is locked.
9. Use SST for inspection or test of the injector or its wiring connector.
  SST 09842-30070
  
  Fig 1: Using SST For Inspecting Injector Or Wiring Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FUEL SYSTEM
1. 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.
    
    Fig 2: Disconnecting Fuel Pump Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    
    Fig 3: Reconnecting Fuel Pump Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When connecting the union bolt on the high pressure pipe union, observe these procedures:
  1. Always use 2 new gaskets.
  2. Tighten the union bolt by hand.
  3. Tighten the union bolt to the specified torque.
    Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf)
    
    Fig 4: Tightening Union Bolt By Hand
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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 the specified torque.
  SST 09023-38400
  
  Torque:
  
  28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST
  
  34.3 N.m (350 kgf.cm, 25 ft.lbf)
  
  NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
  
  Fig 5: Tightening Flare Nut By Torque Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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-never use engine, gear or brake oil.
    
    Fig 6: Removing/Installing New O-Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
  Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector.
  
  Fig 7: Identifying Injector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Quick Type A:
  Observe these precautions when disconnecting the fuel tube connector:
  1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away.
  2. Be sure to disconnect by hands.
  3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time.
  4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away.
  5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag.
    
    Fig 8: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Quick Type A:
  Observe these precautions when connecting the fuel tube connector:
  1. Do not reuse the retainer removed from the pipe.
  2. Must use hands to remove the retainer from the pipe.
  3. Check that there is any damage or foreign objects on the connected part of the pipe.
  4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
    
    Fig 9: Connecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
  6. Check if there is any fuel leakage.
    
    Fig 10: Checking Fuel Leakage
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Quick Type B:
  Observe these precautions when disconnecting the fuel tube connector:
  1. Check that there is any dirt like mud in the pipe and around the connector before disconnecting them and clean the dirt away.
  2. Be sure to disconnect them with hands.
  3. When the connector and the pipe are stuck, push and pull the connector to free them. And then disconnect and pull it out. Do not use any tools at this time.
  4. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.
  5. Prevent the disconnected pipe and connector from being damaged and foreign objects mixing in by covering them with a vinyl bag.
    
    Fig 11: Disconnecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Quick Type B:
  Observe these precautions when connecting the fuel tube connector:
  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 into the connector until the connector makes a "click" sound. In case that the connection is tight, apply little amount of fresh engine oil on the tip of the pipe.
    
    Fig 12: Connecting Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
  4. Check that there is any fuel leak.
    
    Fig 13: Checking Fuel Leakage
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Observe these precautions when handling nylon tube.
  1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them.
  2. Pay attention not to kink the nylon tube.
  3. Do not remove the EPDM protector from the outside of the nylon tube.
  4. Must not close the piping with the nylon tube by bending it.
11. Check that there is any fuel leak after maintenance anywhere on the fuel system.
  1. Connect a hand-held tester to the DLC3.
  2. Turn the ignition switch ON, and push the hand-held tester main switch ON.
    NOTE: Do not start the engine.
  3. Select the ACTIVE TEST mode on the hand-held tester.
  4. Please refer to the hand-held tester operator's manual for further details.
    
    Fig 14: Connecting Hand-Held Tester
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Pinch the fuel return hose.
    The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/cm² , 57 psi). In this state, check to see that there are no leaks from any part of the fuel system.
    
    NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
  6. Turn the ignition switch OFF.
  7. Disconnect the hand-held tester from the DLC3.
    
    Fig 15: Testing Fuel Return Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002