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On-Vehicle Inspection

  1. CHECK FUEL PUMP OPERATION 
    1. Connect the hand-held tester to the DLC3.
    2. Turn the ignition switch to ON.
      NOTE: Do not start the engine.
    3. Turn the hand-held tester main switch ON.
    4. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP/SPD.
    5. Check the fuel operation while operating it with the hand held tester.
      Fig 1: Connecting Hand-Held Tester To DLC3
      G02612612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the fuel pump does not operate, replace the fuel pump.

    6. If you have no hand-held tester, connect the positive (+) lead from the battery to terminal 5 of the connector, and the negative (-) lead to terminal 4.
      NOTE:
      • These tests must be done quickly (for less than 10 seconds) to prevent the coil burnout.
      • Keep the fuel pump as far away from the battery as possible.
      • Always do the switching at the battery side.
    7. Check that there is pressure remaining in the fuel inlet pipe from the fuel line.
      Fig 2: Connecting Positive (+) Lead From Battery To Terminal 5 Of Connector
      G02612613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If there is fuel pressure, you will hear the sound of fuel flow. If there is no fuel pressure, check these parts: Fusible link, Fuses, Main relay, Fuel pump, ECM and Wire harness.

    8. Turn the hand-held tester OFF.
    9. Turn the ignition switch to LOCK.
    10. Disconnect the hand-held tester from the DLC3.
  2. CHECK FUEL PRESSURE 
    1. Prepare a new fuel tube.
      ENGINE TYPE AND PART NO SPECIFICATION

      Engine Type Part No.
      1ZZ-FE 23901-0D040
      2ZZ-GE 23271-22010
      Fig 3: Cutting Protector Of Fuel Tube Protector
      G02612614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a cutter knife, cut the protector of the fuel tube protector as illustrated. Tear the protector by hand, then remove the fuel tube connector.
      NOTE: If the protector is cut too deeply with the cutter, the O-ring of the fuel tube connector will be damaged.
    2. Discharge fuel system pressure (see ON-VEHICLE INSPECTION ).
    3. Using a voltmeter, measure the battery voltage.

      Standard: 9.0 to 14 V 

    4. Disconnect the battery negative terminal.
    5. Remove the fuel pipe clamp No. 1.
    6. Disconnect the fuel tube.
    7. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe to disconnect the fuel tube.
      Fig 4: Pinching Retainer Of Fuel Tube Connector
      G02612615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull them to release.
      Fig 5: Identifying Fuel Tube Connector
      G02612616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install SST and the fuel tube connector into the vehicle.

      SST 09268-41047 (95336-08070), 09268-45014 (09268-41200, 09268-1220, 09268-41250)

    9. Wipe off any split gasoline.
    10. Connect the battery negative terminal.

      Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

      Fig 6: Installing SST And Fuel Tube Connector Into Vehicle
      G02612617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the hand-held tester to the DLC3.
    12. Turn the ignition switch to ON.
    13. Turn the hand-held tester ON.
    14. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP/SPD.
      Fig 7: Connecting Hand-Held Tester To DLC3
      G02612618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. If you have no hand-held tester, connect the positive (+) lead from the battery to terminal 5 of the connector, and the negative (-) lead to terminal 4.
    16. Measure the fuel pressure.

      Standard: 

      304 to 343 kPa (3.1 to 3.5 kgf/cm 2  , 44 to 50 psi) 

      • If the fuel pressure is greater than the standard value, replace the fuel pump.
      • If the fuel pressure is less than the standard value, check the connection of the fuel hose and fuel pump.
      Fig 8: Connecting Positive (+) Lead From Battery To Terminal 5 Of Connector
      G02612619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Disconnect the hand-held tester from the DLC3.
    18. Start the engine.
    19. Measure the fuel pressure when the engine idles.

      Standard: 

      304 to 343 kPa (3.1 to 3.5 kgf/cm 2  , 44 to 50 psi) 

    20. Stop the engine.
    21. After stopping the engine, check that the fuel pressure does not charge for 5 minutes.

      Standard: 

      147 kPa (1.5 kgf/cm 2  , 21 psi) or more 

      If the fuel pressure is not as specified, check that the fuel pump or fuel injector.

    22. Connect the fuel tube.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tube to the pipe.
      NOTE:
      • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tube, check that the fuel tube is securely connected by pulling the fuel tube connector.
      Fig 9: Aligning Fuel Tube Connector With Pipe And Pushing Fuel Tube Connector
      G02612620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    23. Install the fuel pipe clamp No. 1.
    24. Check for Fuel leakage (see ON-VEHICLE INSPECTION )
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