Fuel system (2AZ−FE)(From July, 2003)

ON−VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FUEL LEAKS

a. When using the hand−held tester: Check fuel pump operation.

1. 1
   Connect the hand−held tester to the DLC3.
2. 2
   Turn the ignition switch ON and push the hand−held tester main switch ON.

NOTICE: Do not start the engine.

1. 1
   Select the ACTIVE TEST mode on the hand−held tester.
2. 2
   If you need help to select active test on the hand− held tester, refer to the hand−held tester is instruction manual.
3. 3
   Turn the ignition switch OFF.
4. 4
   Disconnect the hand−held tester from the DLC3.

b When not using the hand−held tester: Check fuel pump operation.

1. 1
   Remove the C/OPN relay from the engine room J/B.
2. 2
   Using a service wire, connect terminals FP and +B of the engine room J/B.

NOTICE: Pay close attention to the terminal connecting position to avoid a malfunction.

3. Turn the ignition switch ON, and check that the fuel pump operates.

NOTICE: Do not start the engine.

1. 1
   Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
2. 2
   Turn the ignition switch OFF.
3. 3
   Remove the service wire from the engine room J/B.
4. 4
   Install the C/OPN relay to the engine room J/B.

   

2. CHECK FUEL PRESSURE

1. 1
   Check that the battery positive voltage is above 12 V.
2. 2
   Disconnect the negative (−) terminal cable from the battery.
3. 3
   Purchase a new fuel tube and take out the fuel tube connector from its pipe.

   Fuel tube: Part No. 23801−20190

   

d. Remove the fuel pipe clamp from the fuel tube connector.

e. Disconnect the fuel tube connector from the fuel pipe by pinching part A with your fingers, as shown in the illustration.

CAUTION:

• Always read the precautions before disconnecting the fuel tube connector (quick type).
• The fuel pipe line may spray fuel as a result of retained pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment.

1. 1
   Install SST (pressure gauge) and fuel tube connecter using SST as shown in the illustration.

   SST 09268−41047 (90467−13001, 95336−08070), 09268−45014 (09268−41200, 09268−41220, 09268−41250)

2. 2
   Wipe off any gasoline.
3. 3
   Reconnect the negative (−) battery cable.
4. 4
   When using hand−held tester: Operate the fuel pump (see step 1 a.).
5. 5
   When not using hand−held tester: Operate the fuel pump (see step 1 b.).
6. 6
   Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi)

If the pressure is high, replace the fuel pressure regulator.

If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator.

1. 1
   Start the engine.
2. 2
   Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi)
3. 3
   Stop the engine.

   

o. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.Fuel pressure: 147 kPa (1.5 kgf/cm2, 21psi)

If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.

1. 1
   After checking the fuel pressure, disconnect the negative (−) battery cable and carefully remove SST and fuel tube connector to prevent gasoline from spraying.
2. 2
   Reconnect the fuel inlet tube (fuel tube connector).

CAUTION: Always read the precautions before connecting the fuel tube connector (quick type).