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On-Vehicle Inspection: Procedure

  1. AFTER SERVICE PRECAUTION 
    WARNING:
    • Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. If fuel comes into contact with the skin and eyes it will cause irritation. To prevent this, perform the following inspections with the engine stopped.
    • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.
    1. Fuel Leakage Inspection

      Using Techstream 

      1. Connect the Techstream to the DLC-2.
      2. Switch the ignition to ON (engine off).
      3. Using the simulation function "Fuel pump", start the fuel pump.

        Refer to ON-BOARD DIAGNOSTIC TEST

      4. Verify that there is no fuel leakage from the serviced parts.

        Standard

        There shall be no leakage after 5 minutes.

      5. In the case of fuel leakage, replace the following components and then recheck using the fuel leakage checking procedure.
        • If there is leakage, replace the fuel hoses and clips.
        • If there is damage on the seal on the fuel pipe side, replace the fuel pipe.

      Without using Techstream 

      1. Disconnect the negative battery cable.

        Refer to REMOVAL

      2. Remove the fuel pump relay.
        NOTE:

        Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.

        GTY483053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Relay and Fuse Block
        *b Fuel Pump Relay
        *c Vehicle Front
      3. Using a jumper wire, short fuel pump relay terminals 5 and 3 in the relay and fuse block.
        GTY487465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Relay and Fuse Block
        (Fuel Pump Relay)
      4. Connect the negative cable and operate the fuel pump.

        Refer to INSTALLATION

      5. Verify that there is no fuel leakage from the serviced parts.

        Standard

        There shall be no leakage after 5 minutes.

      6. In the case of fuel leakage, replace the following components and then recheck using the fuel leakage checking procedure.
        • If there is leakage, replace the fuel hoses and clips.
        • If there is damage on the seal on the fuel pipe side, replace the fuel pipe.
  2. FUEL LINE PRESSURE INSPECTION 
    WARNING:
    • Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.
    • Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION".
    • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.
    NOTE:

    Disconnecting/connecting the fuel tube connector (quick type) without cleaning it may possibly cause damage to the fuel pipe and fuel tube connector (quick type). Always clean the fuel tube connector (quick type) joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free of foreign material.

    1. Complete the "BEFORE SERVICE PRECAUTION".

      Refer to PRECAUTION 

    2. Disconnect the negative battery cable.

      Refer to REMOVAL

    3. Disconnect the fuel tube connector (quick type) as shown in the figure.
      GTY493808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a High Pressure Fuel Pump
      *b Fuel Tube Connector (Quick Type)
      *c Vehicle Front

      Refer to REMOVAL

    4. Turn the lever of the SST parallel to the hose as shown in the figure.
      GTY486776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lever
      *b Vehicle Front
      • SST: 49N0131A0D 
    5. Insert the SST fuel tube connector (quick type) into the fuel pipe until a click is heard.
    6. Verify that the fuel tube connector (quick type) is firmly connected by pulling it by hand.
    7. Start the fuel pump using the following procedure.
    8. Start the fuel pump using the following procedure.

      Using Techstream 

      1. Connect the negative battery cable.

        Refer to INSTALLATION

      2. Connect the Techstream to the DLC-2.
      3. Using the simulation function "Fuel pump", start the fuel pump.

        Refer to ON-BOARD DIAGNOSTIC TEST

      Without using Techstream 

      GTY488698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Relay and Fuse Block
      *b Fuel Pump Relay
      *c Vehicle Front
      1. Remove the fuel pump relay.
        NOTE:

        Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.

      2. Using a jumper wire, short fuel pump relay terminals 5 and 3 in the relay and fuse block.
        GTY487465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Relay and Fuse Block
        (Fuel Pump Relay)
      3. Connect the negative battery cable and operate the fuel pump.

        Refer to INSTALLATION

    9. Operate the fuel pump for 10 seconds.
    10. Measure the fuel line pressure.

      If not within the specification, inspect the following:

      • If it less than the specification:
        • Fuel pump unit
        • Fuel line for restriction or leakage
      • If it exceeds the specification:
        • Fuel line restriction

      Fuel pressure

      425 to 505 kPa (4.4 to 5.1 kgf/cm2 , 62 to 73 psi)

    11. Stop the fuel pump using the following procedure.

      Using Techstream 

      1. Using the simulation function "Fuel pump", stop the fuel pump.

        Refer to ON-BOARD DIAGNOSTIC TEST

      Without using Techstream 

      1. Disconnect the negative battery cable to stop the fuel pump.

        Refer to REMOVAL

    12. Measure the fuel hold pressure after 5 minutes.

      If not within the specification, inspect the following:

      • - Fuel line leakage

      Fuel hold pressure

      250 kPa (2.6 kgf/cm2 , 37 psi) or more

    13. Complete the "BEFORE SERVICE PRECAUTION".

      Refer to PRECAUTION 

    14. Disconnect the SST.
    15. Connect the fuel tube connector (quick type).

      Refer to INSTALLATION

    16. Complete the "AFTER SERVICE PRECAUTION".

      See step  1

  3. FUEL DRAINING PROCEDURE 
    WARNING:
    • Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION".
    • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.
    1. Fuel Siphoning Procedure Using Fuel Pump
      NOTE:

      Disconnecting/connecting the fuel tube connector (quick type) without cleaning it may possibly cause damage to the fuel pipe and fuel tube connector (quick type). Always clean the fuel tube connector (quick type) joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free of foreign material.

      1. Complete the "BEFORE SERVICE PRECAUTION".

        Refer to PRECAUTION 

      2. Disconnect the fuel tube connector (quick type) as shown in the figure.
        GTY491087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a High Pressure Fuel Pump
        *b Fuel Tube Connector (Quick Type)
        *c Vehicle Front

        Refer to REMOVAL

      3. Connect a long hose to the disconnected fuel tube connector (quick type) and drain the fuel into a container used for collecting gasoline.
      4. Drain the fuel from the fuel tank using the following procedure:
        NOTE:

        The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

        Using Techstream 

        1. Connect the Techstream to the DLC-2.
        2. Using the simulation function "Fuel pump", start the fuel pump.

          Refer to ON-BOARD DIAGNOSTIC TEST

          If the fuel pump cannot be operated, remove the fuel using the procedure in the reference.

          See step  3

        Without using Techstream 

        GTY486034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Relay and Fuse Block
        *b Fuel Pump Relay
        *c Vehicle Front
        1. Disconnect the negative battery cable.

          Refer to REMOVAL

        2. Remove the fuel pump relay.
          NOTE:

          Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.

        3. Using a jumper wire, short fuel pump relay terminals 5 and 3 in the relay and fuse block.
          GTY487465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a Relay and Fuse Block
          (Fuel Pump Relay)
        4. Connect the negative battery cable and operate the fuel pump.

          Refer to INSTALLATION

          If the fuel pump cannot be operated, remove the fuel using the procedure in the reference.

          See step  3

      5. Stop the fuel pump using the following procedure.

        Using Techstream 

        1. Using the simulation function "Fuel pump", stop the fuel pump.

          Refer to ON-BOARD DIAGNOSTIC TEST

        2. Disconnect the negative battery cable.

          Refer to REMOVAL

        Without using Techstream 

        1. Remove the jumper wire to stop the fuel pump.
        2. Disconnect the negative battery cable.

          Refer to REMOVAL

    2. Fuel Siphoning Procedure Not Using Fuel Pump
      1. Complete the "BEFORE SERVICE PRECAUTION".

        Refer to PRECAUTION 

      2. Perform the following procedure (1) to (3) if the fuel gauge value is 3/4 or more. If the fuel gauge value is 3/4 or less, go to Step 3.
        NOTE:
        • If an excessive length of hose is inserted into the fuel-filler pipe, the hose will push the roll-over valve and the hose may enter the fuel tank. If the hose enters the fuel tank, the hose may get stuck on the roll-over valve when the hose is pulled and the roll-over valve could be damaged. Do not insert the hose more than the specified length.
        • When removing the hose from the fuel-filler opening, use a rag to prevent fuel spatter.

        HINT: 

        • When removing the hose from the fuel-filler opening, use a rag to prevent fuel spatter.
        • Cut the tip of the hose diagonally so that it can be inserted into the fuel-filler pipe smoothly.
        • When inserting the hose into the fuel-filler pipe, the hose may get stuck. In such cases, rotate the hose so that the hose can be inserted easily.
        • The pump siphons all the fuel that leaked out of the roll-over valve and was trapped in the joint hose, then it suctions the air. After siphoning the fuel, wait several seconds until the air is suctioned out, then resume siphoning.
        1. Cut the tip of the hose diagonally and place a mark at the position of the specified hose insertion length.
          GTY484586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a Hose
          *b Marking
          *c Hose Insertion Length
          (Specified Value)

          Hose insertion length (specified value)

          1240 mm (4.07 ft.)

          Hose type (reference)

          Oil-resistant plastic hose of 10 mm (0.3934 in.) outer diam. x 6 mm (0.236 in.) inner diam. or equivalent

        2. Insert the hose from the fuel-filler opening by rotating it to the marked position.
        3. Using a pump, siphon the fuel until the fuel gauge value reaches 3/4 or less.
      3. Remove the fuel pump unit.

        Refer to REMOVAL

      4. Drain the fuel.
      5. Remove the hose using a rag.
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