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SFI System: Precaution

HINT:

  1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY 
  2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 
  3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 
  4. MAINTENANCE PRECAUTIONS 
    1. In the event of engine misfire, these precautions should be taken.
      1. Check proper connection to battery terminals, etc.
      2. After repairing 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 heated oxygen sensors.
      1. Do not drop the sensor or hit it against an object.
      2. The sensor should be free from any contact with water.
  5. IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) 

    If the vehicle is equipped with a mobile communication system, refer to PRECAUTION in Introduction article.

  6. AIR INDUCTION SYSTEM 
    1. Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine 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 out of tune.
  7. ELECTRONIC CONTROL SYSTEM 
    1. Before removing the 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 the 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 making the inspection during rainy weather, take care to prevent any entry of water. Also, when washing the engine compartment, prevent water from getting into the SFI parts and wiring connectors.
    7. Parts should be replaced with an assembly.
    8. Care should be taken when pulling out and inserting the 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 an inspection or test of the injector or its wiring connector.

      SST 09842-30080

    Fig 1: Testing Injector Wiring Connector Using SST
    G02630948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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.
      3. Put a container under the connection.
      4. Reconnect the fuel pump connector.
      Fig 2: Identifying Fuel Pump Connector
      G02630949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe these precautions when removing and installing the injector.
      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 but never use engine, gear or brake oil.
      Fig 3: Removing And Installing The Injector
      G02630950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the injector to the delivery pipe and cylinder head, as shown in the illustration.
      Fig 4: Installing Injector To Delivery Pipe And Cylinder Head
      G02630951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Observe these precautions when disconnecting the fuel tube connector (quick type):
      1. Disconnect the fuel pipe clamp from the connector.
      2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.
        Fig 5: Disconnecting Fuel Pipe Clamp From Connector
        G02630952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Be sure to disconnect by hand.
      4. When the connector and the pipe are stuck, pinch the retainer by hand, push and pull the connector to free the connection and pull it out. Do not use any tools at this time.
      5. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away.
      6. Prevent the disconnected pipe and connector from being damaged and foreign objects mixing in objects by covering them with a vinyl bag.
      Fig 6: Pulling Out Connector
      G02630953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Observe these precautions when connecting the fuel tube connector (quick type):
      1. Do not reuse the retainer removed from the pipe.
      2. Remove the retainer from the pipe by hand. Do not use any tools.
      3. Check if there is any damage or foreign objects on the connected part of the pipe.
        Fig 7: Identifying Retainer
        G02630954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Match the axis of the connector with the axis of the pipe, and push in the connector until the retainer makes a "click" sound. In case the connection is tight, apply a little amount of new engine oil onto the tip of the pipe.
      5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.
        Fig 8: Pushing Connector Into Pipe
        G02630955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Install the fuel pipe clamp to the connector.
      7. Check if there is any fuel leak.
      Fig 9: Installing Fuel Pipe Clamp To Connector
      G02630956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Observe these precautions when disconnecting the fuel tube connector (metallic type):

      HINT:

      The structure of the metallic connector is shown as left.

      1. Check if there is any dirt like mud in the pipe and around the connector before disconnecting them and remove the dirt if any.
        Fig 10: Identifying Metallic Connector Components
        G02630957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Assemble SST to the connection as shown in the illustration.

        SST 09268-21010

        Fig 11: Assembling SST To Connection
        G02630958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector.
        Fig 12: Inserting SST Into Connector
        G02630959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. While holding the SST, pull the connector towards the SST to put the retainers on the SST chamfered parts.
      5. Slide the SST and the connector together towards the fuel tube assembly.
      Fig 13: Pulling Connector Toward SST
      G02630960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Observe these precautions when connecting the fuel tube connector (metallic type):
      1. Check if 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 in the connector until the connector makes a "click" sound. In case the connection is tight, apply a little amount of fresh engine oil onto the tip of the pipe.
        Fig 14: Pushing Connector Into Pipe
        G02630961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After having finished the connection, check if the pipe and connector are securely connected by pulling them.
      4. Check that there is any fuel leak.
    8. Observe these precautions when handling a nylon tube:
      1. Pay attention not to turn the connected part of the nylon tube and quick connector with tube when connecting them.
      2. Pay attention not to kink the nylon tube.
      3. Do not remove the nylon tube.
      4. Do not close the piping with the nylon tube by bending it.
      Fig 15: Checking For Secure Connection
      G02630962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
      1. Connect a hand-held tester to the DLC3.
        • Connect the hand-held tester to the DLC3.
        • Turn the ignition switch ON and push the hand-held tester main switch ON.
        • Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
        Fig 16: Connecting Hand-Held Tester To DLC3
        G02630963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Do not start the engine.
        • Please refer to the hand-held tester operator's manual for further details.

        If you have no hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See FUEL PUMP ).

      2. Check that there is no leak in any parts of the fuel system.
      3. Turn the ignition switch OFF.
      4. Disconnect the hand-held tester from the DLC3.
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