豐田凱美瑞camry2az-fe燃油系統(tǒng)

FU–1

2AZ-FEFUEL–FUELSYSTEM

FUELSYSTEM

PRECAUTION

1.

PRECAUTION

(a)

Beforeinspectingandrepairingthefuelsystem,disconnectthenegative(-)batteryterminal.

Donotsmokeorworknearfirewhenhandlingthefuelsystem.

Keepgasolineawayfromrubberorleatherparts.

(b)

(c)

2.

DISCHARGEFUELSYSTEMPRESSURECAUTION:

Performthefollowingprocedurestopreventfuelfromspillingoutbeforeremovinganyfuelsystemparts.

Pressurewillstillremaininthefuellineevenafterperformingthefollowingprocedures.Whendisconnectingthefuelline,coveritwithashopragorapieceofclothtopreventfuelfromsprayingorcomingout.

FU

(a)

Disconnectthefuelpumpconnector.

Removetherearseatcushionassembly.

Removetherearfloorserviceholecover.

Disconnectthefuelpumpconnector.

Starttheengine.

Aftertheenginestops,turntheignitionswitchoff.

HINT:

DTCP0171/25(fuelproblem)and/orP0191/49(fuelpressuresensorsignalerror)maybedetected.

Cranktheengineagain.Checkthattheenginedoesnotstart.

Removethefueltankcaptodischargepressurefromthefueltank.

Disconnectthenegative(-)batteryterminal.

Reconnectthefuelpumpconnector.(10)Installtherearfloorserviceholecover.(11)Installtherearseat.

3.

FUELSYSTEM

Whendisconnectingthehighfuelpressureline,alargeamountofgasolinewillspillout,soobservethefollowingprocedures:

Dischargethefuelsystempressure.(step2)

Disconnectthefuelpumptube(SeepageFU-23).

Drainthefuelthatremainsinsidethefuelpumptube.

A129607

FU–2

2AZ-FEFUEL–FUELSYSTEM

Toprotectthedisconnectedfuelpumptubefromdamageandcontamination,coveritwithaplasticbag.

Putacontainerundertheconnectionpart.

(b)

Observethefollowingprecautionswhenremovingandinstallingthefuelinjectors:

NeverreuseanO-ring.

WhenplacinganewO-ringontheinjector,donotdamagetheO-ring.

CoatanewO-ringwithgasolinebeforeinstallingit.

NOTICE:

Donotuseengineoil,gearoilorbrakefluid.

FU

(c)

Installtheinjectortothedeliverypipeandcylinderhead,asshownintheillustration.

NOTICE:

Beforeinstallingtheinjector,besuretoapplygreaseorgasolinetotheplacewherethedeliverypipeorcylinderheadcontactstheO-ringoftheinjector.

(d)

Observethefollowingprecautionswhendisconnectingthefueldeliverypipe(metallictype):HINT:

Thestructureofthemetallicconnectorisshownontheleft.

O-ring Retainer Pipe

Housing

A050709E01

NylonTube

O-Ring

FuelInjector

Insulator FuelDeliveryPipe

A097444E02

CORRECT

INCORRECT

O-Ring DeliveryPipe

A131629E01

PlasticBag

B000679E07

FU–3

2AZ-FEFUEL

–FUELSYSTEM

(1)RemovetheNo.2fuelpipeclamp.HINT:

TheNo.2fuelpipeclampcannotbereused.

Findthemetallicconnectorofthefueltubeassembly.

AssembleSSTtotheconnectionasshownintheillustration.

SST

09268-21010

TurntheSST,aligntheretainersinsidetheconnectorwiththeSSTchamferedpartsandinsertSSTintotheconnector.

SlidetheSSTandtheconnectortogethertowardsthefueltubeassembly.

FU

(e)

Observethefollowingprecautionswhenconnectingthefueltubeconnector(metallictype):

Checkifthereisanydamageorforeignobjectsontheconnectingpartofthepipe.

Matchtheaxisoftheconnectorwiththeaxisofthepipe,andpushintotheconnectoruntiltheconnectormakesa"click"sound.Iftheconnectionistight,applyasmallamountoffreshengineoiltothetipofthepipe.

Afterfinishingtheconnection,checkifthepipeandtheconnectoraresecurelyconnectedbypullingonthem.

Checkforfuelleaks.

Pull

B084645E04

Push

B084645E01

Retainer(at4places)

SST

A130371E01

FuelPipe

A136248E01

FU–4

2AZ-FEFUEL–FUELSYSTEM

(5)InstallanewNo.2fuelpipeclamp.

(f)

Observethefollowingprecautionswhendisconnectingthefueltubeconnectors(QuicktypeA):

RemovetheNo.1fuelpipeclampfromthetubeconnector.

Checkthatthereisnodirtorotherforeignobjectsonthepipeandaroundtheconnectorbeforedisconnectingthem.Cleanthemifnecessary.

FU

Disconnecttheconnectorfromthepipebyhand.

Whentheconnectorandthepipearestuck,pushinandpullontheconnectortoreleaseit.Pulltheconnectoroutofthepipecarefully.

Checkthatthereisnodirtorotherforeignobjectsonthesealingsurfaceofthedisconnectedpipe.Cleanitawayifnecessary.

(6)Donotdamagethedisconnectedpipeandconnector,andprevententryofforeignobjectsbycoveringthemwithaplasticbag.

QuickTypeA

PlasticBag

B009222E04

QuickTypeA

A088336E10

No.1FuelPipeClamp

A060083E16

FuelPipe

A136248E02

FU–5

2AZ-FEFUEL–FUELSYSTEM

(g)

Observethefollowingprecautionswhenconnectingthefueltubeconnectors(QuickTypeA):

Checkifthereisanydamageorforeignobjectsontheconnectingpartsofthepipes.

Lineupthetwopartsofthepipestobeconnected,andpushthemtogetheruntiltheconnectormakesa"click"sound.Ifthepipeisdifficulttopushintotheconnector,applyasmallamountofcleanengineoiltothetipofthepipeandreinsertit.

Afterconnectingthepipes,checkthatthepipeandconnectoraresecurelyconnectedbypullingonthem.

Checkforfuelleaks.

FU

(h)

Observethefollowingprecautionswhendisconnectingthefueltubeconnector(QuicktypeB):

Beforedisconnectingtheconnector,cleanoffanydirtthatmaybepresent.

Pinchthetabsofthefueltuberetainertodisengagethe2claws.Pushtheretainerdownasshownintheillustration.

HINT:

Besuretodisconnecttheconnectorbyhand.

Iftheconnectorandpipearestuck,holdthefuelpipebyhandandpushandpullontheconnector.Pullthetwopipesaparttoseparatetheconnector.

Ifthereisanydirtoranyotherforeignobjectsonthesealingsurfacesofthedisconnectedpipes,cleanthemifnecessary.

(5)Donotdamagethedisconnectedpipeandconnector,andprevententryofforeignobjectsbycoveringthemwithaplasticbag.

QuickTypeB

PlasticBag

A093309E03

QuickTypeB

A091246E06

QuickTypeB

A129459E01

QuickTypeA

Push

Pull

A121423E01

FU–6

2AZ-FEFUEL–FUELSYSTEM

(i)

Observethefollowingprecautionswhenconnectingthefueltubeconnector(QuickTypeB):

Lineupthetwopartsofthepipestobeconnected,andfullypushthefueltubeconnectorandpipetogetheruntiltheyarefullyseated.Next,pushtheretainerintotheconnectoruntilitsclawslock.Ifthepipeisdifficulttopushintotheconnector,applyasmallamountofcleanengineoiltothetipofthepipeandreinsertit.

Afterconnectingthepipes,checkthatthepipeandconnectoraresecurelyconnectedbypullingonthem.

Checkforfuelleaks.

Observethefollowingprecautionswhenhandlinganylontube:

CAUTION:

(j)

?

Donottwisttheconnectionpartofthenylontubeandthequickconnectorwhenconnectingthem.

Donotbendortwistthenylontube.

DonotremovetheEPDMprotectorontheoutsideofthenylontube.

Donotclosethepipingbybendingthenylontube.

FU

?

?

?

4.

CHECKFORFUELLEAKS

(a)Checkthattherearenofuelleaksfromthefuelsystemafterdoinganymaintenanceorrepairs(SeepageFU-9).

QuickTypeB

A132390E01

FU–7

2AZ-FEFUEL

–

FUELSYSTEM

PARTSLOCATION

FU

FUELPUMP

ECM ENGINEROOMRELAYBLOCK

FUELINJECTOR

A136012E01

FU–8

2AZ-FEFUEL–FUELSYSTEM

SYSTEMDIAGRAM

FU

ECM

C7FuelInjector(No.1)

INJ 108

1 2 C24

C9FuelInjector(No.2)

E23IgnitionSwitch 107

1 2 C24

6 IG2 AM2 5

C8FuelInjector(No.3)

106

ST/AM2 C24

From 1 2

Battery

C10FuelInjector(No.4)

105

1 2 C24

EFIMAIN

FromBattery

EFI

44

A24

N10FuelSuctionPumpandGaugeAssembly

5 4 C/OPN

Pump

IGN 7

A24

A136724E01

#10

#20

#30

#40

MREL

FC

FU–9

2AZ-FEFUEL–FUELSYSTEM

ON-VEHICLEINSPECTION

1.

CHECKFUELPUMPOPERATIONANDFORFUELLEAKS

(a)

Checkfuelpumpoperation.

(1)

(2)

ConnecttheintelligenttestertotheDLC3.TurntheignitionswitchtotheONpositionandpushtheintelligenttestermainswitchon.

NOTICE:

Donotstarttheengine.

Selectthefollowingmenuitems:DIAGNOSIS/ENHANCEDOBDII/ACTIVETEST/FUELPUMP/SPD.

Checkforpressureinthefuelinlettubefromthefuelline.Checkthatsoundoffuelflowinginthefueltankcanbeheard.Ifnosoundcanbeheard,checktheintegrationrelay,fuelpump,ECMandwiringconnector.

(3)

(4)

(b)

Checkforfuelleaks.

(1)Checkthattherearenofuelleaksanywhereonthesystemafterperformingmaintenance.Ifthereisafuelleak,repairorreplacepartsasnecessary.

Turntheignitionswitchoff.

DisconnecttheintelligenttesterfromtheDLC3.

FU

(c)

(d)

2.

CHECKFUELPRESSURE

(a)

Usingavoltmeter,measurethebatteryvoltage.

Standardvoltage:

11to14V

Dischargethefuelsystempressure(SeepageFU-1).

Disconnectthecablefromthenegative(-)batteryterminal.

RemovetheNo.1fuelpipeclampfromthefueltubeconnector.

Disconnectthefuelhosefromthefuelmaintube.

CAUTION:

Alwaysreadtheprecautions(SeepageFU-1)beforedisconnectingthefueltubeconnector(quicktype).

Thefuelpipelinemaysprayfuelasaresultofretainedpressurethatremainsinit.Donotallowfueltobesprayedintheenginecompartment.

(b)

(c)

(d)

(e)

No.1FuelPipeClamp

A060083E16

FU–10

2AZ-FEFUEL–FUELSYSTEM

(f)

InstallSST(pressuregauge)andthefueltubeconnectorusingSSTasshownintheillustration.

SST

09268-31011(09268-41500,90467-13001,

95336-08070),09268-45014(09268-41200,

09268-41220,09268-41250)

(g)

(h)

Wipeupanygasoline.

Reconnectthecabletothenegative(-)batteryterminal.

Selectthefollowingmenuitems:DIAGNOSIS/ENHANCEDOBDII/ACTIVETEST/FUELPUMP

/SPD.

Measurethefuelpressure.

Fuelpressure:

304to343kPa(3.1to3.5kgf/cm2,44.1to49.7psi)

Ifthepressureishigh,replacethefuelpressureregulator.

Ifthepressureislow,checkthefuelhosesandconnections,fuelpump,fuelfilterandfuelpressureregulator.

DisconnecttheintelligenttesterfromtheDLC3.Starttheengine.

Measurethefuelpressureatidle.

Fuelpressure:

304to343kPa(3.1to3.5kgf/cm2,44.1to49.7psi)

Stoptheengine.

Checkthatthefuelpressureremainsasspecifiedfor5minutesaftertheenginehasstopped.

Fuelpressure:

147kPa(1.5kgf/cm2,21psi)ormore

Ifthepressureisnotasspecified,checkthefuelpump,pressureregulatorand/orinjectors.

Aftercheckingthefuelpressure,disconnectthecablefromthenegativebatteryterminalandcarefullyremovetheSSTtopreventgasolinefromsplashing.

Reconnectthefuelmaintube(fueltubeconnector).

CAUTION:

Alwaysreadtheprecautions(SeepageFU-1)beforeconnectingthefueltubeconnector(quicktype).

InstalltheNo.1fuelpipeclamptothefueltubeconnector.

Checkforfuelleaks(Step1).

(i)

(j)

FU

(k)

(l)

(m)

(n)

(o)

(p)

(q)

(r)

(s)

SST(Clip) SST(PressureGauge)

SST(T-joint)

SST(Tube)

SST

(Hose)

SST(TubeConnector)

A105669E04

FU–11

2AZ-FEFUEL

–

FUELINJECTOR

FUELINJECTOR

COMPONENTS

FU

PURGEVSV

NO.2VENTILATIONHOSE VACUUMHOSEAIRCLEANERCAPSUB-ASSEMBLY

ENGINEWIRE

FUELDELIVERYPIPE

WITHINJECTOR 20(204,15)

SPACER

PURGEVSVVACUUMHOSE

O-RING

FUELINJECTOR

INSULATOR ASSEMBLY

NO.2VENTILATION NO.1FUELPIPECLAMP

HOSE

NO.1ENGINECOVERSUB-ASSEMBLY

:SpecifiedtorqueNon-reusablepart

A136019E01

N*m(kgf*cm,ft.*lbf)

7.0(71,62in.*lbf)

FU–12

2AZ-FEFUEL–FUELINJECTOR

REMOVAL

1.

DISCHARGEFUELSYSTEMPRESSURE

HINT:

SeepageFU-1.

DISCONNECTCABLEFROMNEGATIVEBATTERYTERMINAL

REMOVEAIRCLEANERCAPSUB-ASSEMBLY(See

pageES-416)

REMOVENO.1ENGINECOVERSUB-ASSEMBLY

(SeepageEM-94)

DISCONNECTFUELTUBESUB-ASSEMBLY

2.

3.

4.

5.

(a)

RemovetheNo.1fuelpipeclamp.

NOTICE:

Checkforforeignmatteronthepipeandaroundtheconnectorbeforedisconnectingthequickconnector.Cleantheconnectorifnecessary.

FU

(b)

Iftheconnectorandpipearestuck,pinchtheconnector,andpushandpullthepipetodisconnectthem.

NOTICE:

Donotuseanytoolsinthisprocedure.

Checkforforeignmatteronthesealingsurfaceofthedisconnectedpipe.Cleanitifnecessary.

(c)

Separatethefueltubefromthefuelhoseclamp.

A136017E01

Pull

Pinch

Pinch

A136016E01

A136015E01

FU–13

2AZ-FEFUEL–FUELINJECTOR

6.

DISCONNECTNO.2VENTILATIONHOSE

(a)DisconnecttheNo.2ventilationhosefromtheventilationvalve.

7.

REMOVEFUELDELIVERYPIPEWITHINJECTOR

(a)

(b)

Removethe2wireharnessclamps.Disconnectthe4fuelinjectorconnectors.

FU

(c)

Removethe2bolts,thenremovethefueldeliverypipetogetherwiththe4fuelinjectors.

NOTICE:

Becarefulnottodropthefuelinjectorswhenremovingthefueldeliverypipe.

(d)

Removethe2deliverypipespacersfromthecylinderhead.

Removethe4insulatorsfromthecylinderhead.

(e)

8.

REMOVEFUELINJECTORASSEMBLY

Pulloutthe4injectorsfromthedeliverypipe.

Removethe4O-ringsfromtheinjectors.

PullOut

A097399E02

A128737

A136751

A136750

A097786

FU–14

2AZ-FEFUEL–FUELINJECTOR

INSPECTION

1.

INSPECTFUELINJECTORASSEMBLY

(a)

Measuretheresistancebetweentheinjectorterminals.

Standardresistance:

11.6to12.4at20C(68F)

Iftheresultisnotasspecified,replacetheinjector.Inspecttheinjectorinjectionvolume.

CAUTION:

Keeptheinjectorawayfromsparksduringthistest.

(b)

(1)

ConnectSST(fueltubeconnector)toSST(hose),thenconnectthemtothefuelpipe(vehicleside).

SST

09268-31011(09268-41500,90467-

13001,95336-08070)

(2)

InstalltheO-ringtothefuelinjector.

FU

(3)

ConnectSST(adapterandhose)totheinjector,andholdtheinjectorandunionwithSST(clamp).

SST

09268-31011(09268-41110,09268-

41300,90467-13001)

(4)

Puttheinjectorintothegraduatedcylinder.

CAUTION:

Installasuitablevinyltubeontotheinjectortocontaingasolinespray.

Operatethefuelpump.

(5)

(6)

ConnectSST(wire)totheinjectorandthebatteryfor15seconds,andmeasuretheinjectionvolumewiththegraduatedcylinder.Testeachinjector2or3times.

SST

09842-30080

Standardinjectionvolume:

76to92cm3(4.6to5.6cuin.)per15seconds

Standarddifferencebetweeneachinjector:

16cm3(0.98cuin.)orless

SST

(Wire)

Connect

A075915E04

SST SST

Tube

A116183E02

SST(Clip) FuelTube

SST(TubeConnector)

SST(Hose)

A088228E08

Ohmmeter

A116182E01

FU–15

2AZ-FEFUEL–FUELINJECTOR

(c)Inspectthefuelleakage.

(1)

DisconnecttheSST(wire)testerprobesfromthebatteryandcheckthefuelleakagefromtheinjector.

Standardfueldrop:

1droporlessper12minutes

Turntheignitionswitchoff.

Disconnectthecablefromthenegative(-)batteryterminal.

RemovetheSST.

DisconnecttheintelligenttesterfromtheDLC3.Reconnectthefuelinlethose(rearfuelpipe)to

(2)

(3)

(4)

(5)

(6)

thefuelmaintube.

INSTALLATION

1.

INSTALLFUELINJECTORASSEMBLY

(a)

ApplyalightcoatofgasolineorspindleoiltonewO-rings,theninstalloneontoeachfuelinjector.

FU

(b)

ApplyalightcoatofgasolineorspindleoiltothepartofthefueldeliverypipewhichcomesintocontactwiththeO-ringofthefuelinjector.

ApplyalightcoatofgasolineorspindleoiltotheO-ringagain,theninstalltherightandleftfuelinjectorsontothefueldeliverypipe.

NOTICE:

MakesurethattheO-ringisnotcrackedorjammedbeforeinstallingtheinjector.

Checkthatthefuelinjectorrotatessmoothly.Ifthefuelinjectordoesnotrotate,replacetheO-ring.

(c)

(d)

2.

INSTALLFUELDELIVERYPIPEWITHINJECTOR

Install4newinsulatorsintothecylinderhead.

Installthe2deliverypipespacersontothecylinderhead.

A128737

CORRECT

INCORRECT

O-Ring DeliveryPipe

A131629E01

NewO-Ring

A097400E02

A116184

FU–16

2AZ-FEFUEL–

FUELINJECTOR

(c)

Installthefueldeliverypipetogetherwiththe4fuelinjectors,thentemporarilytightenthe2bolts.

NOTICE:

Becarefulnottodropthefuelinjectorswheninstallingthefueldeliverypipe.

Checkthatthefuelinjectorrotatessmoothly.

Ifthefuelinjectordoesnotrotatesmoothly,replacetheO-ring.

(d)

(e)

Tightenthe2boltstothespecifiedtorque.

Torque:20N*m(204kgf*cm,15ft.*lbf)

FU

(f)

(g)

Connectthe4fuelinjectorconnectors.Installthe2wireharnessclamps.

INSTALLNO.2VENTILATIONHOSE

(a)Connecttheventilationhosetotheventilationvalve.

NOTICE:

Makesurethatthepaintmarkandhoseclamparepositionedasshownintheillustrationafterconnectingthehose.

3.

4.

CONNECTFUELTUBESUB-ASSEMBLY

(a)Installthefueltubetothefuelhoseclamp.

A136017E01

WhitePaintMark UP“A”

LH

A095428E03

View:“A”

A136750

A136751

O-Ring

FuelInjector

Insulator FuelDeliveryPipe

A097444E02

FU–17

2AZ-FEFUEL–

FUELINJECTOR

(b)

Pushthefueltubeconnectoruntilitmakesa"click"sound.

(c)

InstalltheNo.1fuelpipeclamp.

5.

INSTALLAIRCLEANERCAPSUB-ASSEMBLY(See

pageES-419)

CONNECTCABLETONEGATIVEBATTERYTERMINAL

CHECKFORFUELLEAKS

HINT:

SeepageFU-9.

INSTALLNO.1ENGINECOVERSUB-ASSEMBLY

(SeepageEM-121)

6.

7.

FU

8.

A136015E01

Push

A103968E03

FU–18

2AZ-FEFUEL–FUELPRESSUREPULSATIONDAMPER

FUELPRESSUREPULSATIONDAMPER

COMPONENTS

FU

NO.1ENGINECOVERSUB-ASSEMBLYPURGEVSVVACUUMHOSE

AIRCLEANERCAPSUB-ASSEMBLY

NO.2VENTILATIONHOSE

NO.2FUELPFUELPRESSUREPULSATIONDAMPERAS

RCLEANER PURGEVSVLTERELEMENT VACUUMHOSE

MBLY

:SpecifiedtorqueNon-reusablepart

A141106E01

N*m(kgf*cm,ft.*lbf)

IPECLAMPSEMBLY

9.0(92,80in.*lbf)

AF

FUELTUBESUB-

SS

9.0(92,80in.*lbf)

FU–19

2AZ-FEFUEL

–

FUELPRESSUREPULSATIONDAMPER

REMOVAL

1.

DISCHARGEFUELSYSTEMPRESSURE

HINT:

SeepageFU-1.

DISCONNECTCABLEFROMNEGATIVEBATTERYTERMINAL

REMOVENO.1ENGINECOVERSUB-ASSEMBLY

(SeepageEM-94)

REMOVEAIRCLEANERCAPSUB-ASSEMBLY(See

pageES-416)

DISCONNECTFUELTUBESUB-ASSEMBLY

HINT:

Disconnectthemetallictypeconnector(SeepageFU-1).

REMOVEFUELPRESSUREPULSATIONDAMPERASSEMBLY

(a)Removethe2boltsandfuelpressurepulsationdamper.

2.

3.

4.

5.

6.

FU

INSTALLATION

1.

INSTALLFUELPRESSUREPULSATIONDAMPERASSEMBLY

(a)ApplyalightcoatofgasolineorspindleoiltotheO-ringofthefuelpressurepulsationdamper.

(b)Installthefuelpressurepulsationdamperwiththe2bolts.

Torque:9.0N*m(90kgf*cm,80in.*lbf)NOTICE:

MakesurethattheO-ringisnotcrackedorjammedbeforeinstallingthedamper.

INSTALLFUELTUBESUB-ASSEMBLY

HINT:

Connectthemetallictypeconnector(SeepageFU-1).

INSTALLAIRCLEANERCAPSUB-ASSEMBLY(See

pageES-419)

CONNECTCABLETONEGATIVEBATTERYTERMINAL

2.

3.

4.

A125338

O-Ring

A125339E01

A125338

FU–20

2AZ-FEFUEL

–

FUELPRESSUREPULSATIONDAMPER

5.

CHECKFORFUELLEAKS

HINT:

SeepageFU-9.

INSTALLNO.1ENGINECOVERSUB-ASSEMBLY

(SeepageEM-121)

6.

FU

FU–21

2AZ-FEFUEL

–

FUELPUMP

FUELPUMP

COMPONENTS

FU

REARSEATCUSHIONASSEMBLY

FUELPUMPTUBESUB-ASSEMBLY REARFLOORSERVICEHOLECOVERCLIP

5.9(60,52in.*lbf)

x8

FUELTANKVENTTUBESETPLATE

FUELSUCTIONTUBEASSEMBLYWITHPUMPANDGAUGE

GASKET

:SpecifiedtorqueNon-reusablepart

A136244E01

N*m(kgf*cm,ft.*lbf)

FU–22

2AZ-FEFUEL–FUELPUMP

FUELNO.1SUCTIONSUPPORT

FUELSUCTIONPLATESUB-ASSEMBLY

FU

SPRING

FUELPUMPHARNESS

O-RING

E-RING

O-RING

FUELPRESSUREREGULATORASSEMBLY

FUELPUMP

FUELNO.1TANKBANDBRACKET

FUELSENDERGAUGEASSEMBLY

Non-reusablepart

A136245E01

FU–23

2AZ-FEFUEL–FUELPUMP

REMOVAL

1.

DISCHARGEFUELSYSTEMPRESSURE

HINT:

SeepageFU-1.

DISCONNECTCABLEFROMNEGATIVEBATTERYTERMINAL

REMOVEREARSEATCUSHIONASSEMBLY(for

FixedSeatType)(SeepageSE-77)

REMOVEREARSEATCUSHIONASSEMBLY(for

FoldDownSeatType)(SeepageSE-47)

REMOVEREARSEATCUSHIONASSEMBLY(for

RecliningSeatType)(SeepageSE-62)

REMOVEREARFLOORSERVICEHOLECOVER

Removetherearfloorserviceholecover.

Disconnectthefuelpumpconnector.

2.

3.

4.

5.

6.

FU

7.

SEPARATEFUELPUMPTUBESUB-ASSEMBLY

(a)Removethetubejointclip,andpulloutthefuelpumptube.

NOTICE:

?

Checkthatthereisnodirtaroundthefueltubejointbeforethisworkandcleananydirtaway.

Itisnecessarytopreventmudordirtfromenteringthefueltubejoint.Ifmudentersthejoint,theO-ringsmaynotsealthefueltubeconnectorandfuelsuctionplateproperly.

Donotuseanytoolsinthiswork.Donotbendortwistthenylontube.

Afterdisconnecting,coverthefueltubejointwithaplasticbag.

Ifthefueltubejointandfuelsuctionplatearestuck,pinchthefueltanktubebetweenfingers,andturnitcarefullytorelease.

Disconnectthefueltanktube.

?

?

?

?

?

TubeJointClip

NylonTube

FuelTubeJoint

O-Ring

TubeJointClip

A129479E02

A129478

FU–24

2AZ-FEFUEL–FUELPUMP

8.

REMOVEFUELTANKVENTTUBESETPLATE

(a)Removethe8boltsandsetplate.

9.

REMOVEFUELSUCTIONTUBEASSEMBLYWITHPUMPANDGAUGE

Pulloutthefuelsuctiontubefromthefueltank.

NOTICE:

Donotdamagethefuelpumpfilter.

Becarefulthatthearmofthesendergaugedoesnotbend.

FU

(b)Removethegasketfromthefuelsuctiontube.

DISASSEMBLY

1.

REMOVEFUELSENDERGAUGEASSEMBLY

(a)Disconnectthefuelsendergaugeconnector.

A136021

Gasket

A136023E01

A139190

A129480

FU–25

2AZ-FEFUEL–FUELPUMP

(b)Unlockthefuelsendergauge,andslideittoremove.

2.

REMOVEFUELNO.1TANKBANDBRACKET

(a)

Usingneedlenozzlepliers,removetheE-ring.

FU

(b)

Disengagethe4clawsofthefuelNo.1suctionsupportandremovethefuelNo.1tankbandbracketfromthefuelsuctionplatewiththefuelfilter.Removethespringfromthefuelsuctionplate.

(c)

3.

REMOVEFUELNO.1SUCTIONSUPPORT

(a)Usingascrewdriverwiththetiptaped,disengagetheclawandremovethefuelNo.1suctionsupport.

A136233

A136232

E-Ring

A136234E01

A136022

FU–26

2AZ-FEFUEL–FUELPUMP

4.

DISCONNECTFUELPUMPHARNESS

(a)Disconnectthefuelpumpharnessconnectorfromthefuelsuctionplate.

5.

REMOVEFUELPUMP

(a)

Usingascrewdriverwithitstiptaped,disengagethe5clawsandpulloutthefuelpumpfromthefuelfilterassembly.

NOTICE:

Donotdamagethefuelpumpfilter.

Donotremovethesuctionfilter.

FU

(b)

Removethefuelpumpharnessconnector.

(c)

RemovetheO-ringfromthefuelpump.

O-Ring

A136238E01

A136237

A136239E01

A136231

FU–27

2AZ-FEFUEL–FUELPUMP

6.

REMOVEFUELPRESSUREREGULATORASSEMBLY

(a)Usingascrewdriverwithitstiptaped,removethefuelpressureregulatorfromthefuelfilter.

(b)Removethe2O-ringsfromthefuelpressureregulator.

FU

INSPECTION

1.

INSPECTFUELPUMP

(a)

Checkthefuelpumpresistance.

(1)Measuretheresistancebetweenterminals1and2.

Standardresistance:

0.2to3.0at20C(68F)

Iftheresultisnotasspecified,replacethefuelpump.

Checkfuelpumpoperation.

(1)Applybatteryvoltagetoterminals1and2.Checkthatthepumpoperates.

NOTICE:

(b)

?

Thesetestsmustbecompletedwithin10secondstopreventthecoilfromburningout.

Keepthefuelpumpasfarawayfromthebatteryaspossible.

Alwaysswitchthevoltageonandoffonthebatteryside,notonthefuelpumpside.

?

?

Ifthepumpdoesnotoperate,replacethefuelpump.

A126943

O-Ring

A096585E03

A136235

FU–28

2AZ-FEFUEL–FUELPUMP

REASSEMBLY

1.

INSTALLFUELPRESSUREREGULATORASSEMBLY

(a)Applyalightcoatofgasolineto2newO-rings,andinstallthemtothefuelpressureregulator.

(b)Installthefuelpressureregulatortothefuelfilter.

FU

2.

INSTALLFUELPUMP

(a)ApplygasolinetoanewO-ringandinstallittothefuelfilter.

(b)Connectthefuelpumpharnessconnector.

A126130

NewO-Ring

A131633E01

PressureRegulator

A136236E01

O-Ring

A096585E03

FU–29

2AZ-FEFUEL–FUELPUMP

(c)Engagethe5clawsonthefuelfilterandinstallthefuelpumpwiththepumpfilter.

3.

CONNECTFUELPUMPHARNESS

(a)Connectthefuelpumpharnessconnectorfromthefuelsuctionplate.

FU

4.

INSTALLFUELNO.1SUCTIONSUPPORT

(a)InstallthefuelNo.1suctionsupporttothefuelfilter.

INSTALLFUELNO.1TANKBANDBRACKET

5.

(a)

InstallthespringtothefuelsuctionplateshaftandinstallthemtothefuelNo.1tankbandbracket.

Engagethe4clawsofthefuelNo.1suctionsupportandinstallthefuelNo.1tankbandbrackettothefuelsuctionplatewiththefuelfilter.

(b)

(c)

InstallanewE-ring.

E-Ring

A136234E01

A136233

A136231

A136240

FU–30

2AZ-FEFUEL–FUELPUMP

6.

INSTALLFUELSENDERGAUGEASSEMBLY

(a)

Slidethefuelsendergaugetoengagetheclaw.

(b)

Connectthefuelsendergaugeconnector.

FU

INSTALLATION

1.

INSTALLFUELSUCTIONTUBEASSEMBLYWITHPUMPANDGAUGE

(a)Installanewgaskettothefuelsuctiontube.

Installthefuelsuctiontube.

NOTICE:

Donotdamagethefuelpumpfilter.

Becarefulthatthearmofthesendergaugedoesnotbend.

A139190

Gasket

A136023E01

A136021

A136241

FU–31

2AZ-FEFUEL–FUELPUMP

2.

INSTALLFUELTANKVENTTUBESETPLATE

Alignthemarkofthesetplatewiththefuelsuctiontube.

Installthesetplatewiththe8bolts.

Torque:5.9N*m(60kgf*cm,52in.*lbf)

3.

CONNECTFUELPUMPTUBESUB-ASSEMBLY

(a)Installthefuelpumptubewiththetubejointclip.

NOTICE:

?

Checkthattherearenoscratchesorforeignobjectsontheconnectingpart.

Checkthatthefueltubejointisinsertedsecurely.

Checkthatthetubejointclipisonthecollarofthefueltubejoint.

Afterinstallingthetubejointclip,checkthatthefueltubejointispulledoff.

?

?

FU

?

4.

CONNECTCABLETONEGATIVEBATTERYTERMINAL

CHECKFORFUELLEAKS(SeepageFU-8)

5.

6.

INSTALLREARFLOORSERVICEHOLECOVER

Connectthefuelpumpconnector.

Installtherearfloorserviceholecoverwithnewbutyltape.

INSTALLREARSEATCUSHIONASSEMBLY(for

FixedSeatType)(SeepageSE-84)

INSTALLREARSEATCUSHIONASSEMBLY(forFold

DownSeatType)(SeepageSE-58)

INSTALLREARSEATCUSHIONASSEMBLY(for

RecliningSeatType)(SeepageSE-73)

7.

8.

9.

A129478

FuelMainTube

FuelTubeJoint

O-Ring FuelTube

TubeJointClip

TubeJointClip Collars

Collars

CORRECT INCORRECT

A139189E01

Mark

A129480E01

FU–32

2AZ-FEFUEL

–

FUELTANK

FUELTANK

COMPONENTS

FU

REARSEATCUSHIONASSEMBLY

FUELPUMPTUBESUB-ASSEMBLY REARFLOORSERVICEHOLECOVERCLIP

5.9(60,52in.*lbf)

x8

FUELTANKVENTTUBESETPLATE

FUELSUCTIONTUBEASSEMBLYWITHPUMPANDGAUGE

GASKET

:SpecifiedtorqueNon-reusablepart

A136244E01

N*m(kgf*cm,ft.*lbf)

FU–33

2AZ-FEFUEL

–FUELTANK

NO.1FUELTUBE

FUELTANKASSEMBLY

FUELTANKTOFILLERPIPEHOSE

FUELTANKPROTECTORLOWERCENTER

x4

FU

PIN

FUELTANKBAND

NO.2PARKINGBRAKECABLEASSEMBLY

FUELTANKBAND

PIN

8.5(87,75in.*lbf)

GASKET

NO.3PARKINGBRAKECABLEASSEMBLY

GASKET

CENTEREXHAUSTPIPEASSEMBLY

56(571,41)

:Specifiedtorque

Non-reusablepart

A136747E01

N*m(kgf*cm,ft.*lbf)

43(438,32)

8.5(87,75in.*lbf)

6.0(61,53in.*lbf)

6.0(61,53in.*lbf)

39(400,29)

39(400,29)

5.4(55,48in.*lbf)

ForSEGrade:

FUELTANKPROTECTORLOWERCENTER

FU–34

2AZ-FEFUEL

–

FUELTANK

FU

FUELPUMPTUBESUB-ASSEMBLY

FUELTANKASSEMBLY

NO.2FUELTANK X7

CUSHION FUELTANKVENTHOSE

CL