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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 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.

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

      Fig 1: Connecting Hand-Held Tester To DLC3
      G02678129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      Fig 2: Connecting Positive (+) Lead From Battery To Terminal Of Connector, And Negative (-) Lead To Terminal (FF)
      G02678130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

      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.
      Fig 3: Connecting Positive (+) Lead From Battery To Terminal Of Connector, And Negative (-) Lead To Terminal (4WD)
      G02678131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CHECK FUEL PRESSURE 
    1. Prepare a new fuel tube.
      FUEL TUBE SPECIFICATION

      Engine Type Part No.
      1ZZ-FE(FF) 23901 -OD040
      1ZZ-FE(4WD) 23901 -OD010
      2ZZ-GE 23271-22010
      Fig 4: Cutting Protector Of Fuel Tube Protector
      G02678132Courtesy 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 FUEL SYSTEM ).
    3. Using a voltmeter, measure the battery voltage.

      Standard: 9.0 to 14V 

    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 5: Pulling Fuel Tube Connector Out Of Pipe To Disconnect Fuel Tube
      G02678133Courtesy 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 to release them.
      Fig 6: Identifying Fuel Tube Connector
      G02678134Courtesy 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, 09268-41220, 09268-41250)

    9. (i) Wipe off any split gasoline.
    10. (j) Connect the battery negative terminal.

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

      Fig 7: Installing SST And Fuel Tube Connector Into Vehicle
      G02678135Courtesy 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 8: Connecting Hand-Held Tester To DLC3
      G02678136Courtesy 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 pst) 

      • 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 9: Connecting Positive (+) Lead From Battery To Terminal 5 Of Connector, And Negative (-) Lead To Terminal 4 (FF)
        G02678137Courtesy 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.

      Fig 10: Connecting Positive (+) Lead From Battery To Terminal 5 Of Connector, And Negative (-) Lead To Terminal 4 (4WD)
      G02678138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 11: Installing Fuel Pipe Clamp No. 1
        G02678139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    23. Install the fuel pipe clamp No. 1.
    24. Check for fuel leakage (see FUEL SYSTEM ).
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