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SFI System: Precaution

WARNING: This page is about a different car, the 2005 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Any diagnostic trouble code (DTC) retained in the ECM will be erased when the negative (-) terminal cable is removed from the battery. If necessary, read the DTC before removing the negative (-) terminal cable from the battery.

  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. To prevent engine misfire, these precautions should be taken.
      1. Check the battery terminals for proper connection.
      2. After repair, 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. Observe the following 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 COMMUNICATION SYSTEM (HAM, CB, ETC.) 

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

  6. AIR INDUCTION SYSTEM 
    1. Removal of the engine oil dipstick, oil filler cap, PCV hose may break the engine.
    2. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head may allow air suction and break the engine.
  7. ELECTRONIC CONTROL SYSTEM 
    1. Before removing the SFI wiring connectors, terminals, first disconnect the power by turning the ignition switch OFF or disconnecting the negative (-) terminal cable from the battery.

      HINT:

      Be sure to check the DTC 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 give a severe impact to the SFI parts during removal or installation. Handle all the SFI parts carefully, especially the ECM.
    4. Be careful during troubleshooting. Numerous transistor circuits are used and even slight terminal contact can cause further troubles.
    5. Do not open the ECM cover.
    6. When inspecting during rainy weather, take care to prevent 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 as 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 the inspection or test of the injector or its wiring connector.

      SST 09842-30080

      Fig 1: Identifying Injector Test Harness SST
      G02639354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. FUEL SYSTEM 
    1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. 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. Slowly loosen the connection.
      5. Disconnect the high fuel pressure line.
      6. Reconnect the fuel pump connector.
        Fig 2: Disconnecting Fuel Pump Connector
        G02639355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe the following 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 anyway.
      3. Coat a new O-ring with spindle oil or gasoline before installing. Never use engine oil, gear oil and brake oil.
    3. Install the injector to the delivery pipe and cylinder head.
      Fig 3: Identifying Proper Injector Installation
      G02639356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 4: Installing Injector To Cylinder Head
      G02639357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Observe the following when disconnecting the fuel tube connector (quick type):
      1. Check if there is any dirt like mud in the pipe and around the connector before disconnecting the fuel tube connector. If necessary, clean the dirt away.
      2. Disconnect the fuel pipe clamp from the connector.
        Fig 5: Disconnecting Fuel Pipe Clamp From Connector (Quick Type)
        G02639358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Be sure to disconnect them with hands.
      4. When the connector and the pipe are stuck, push and pull the connector. Then disconnect and pull it out. Do not use any tools at this time.
      5. Check if there is any dirt on the seal surface of the disconnected pipe. If necessary, clean the dirt away.
      6. Prevent the disconnected pipe and connector from being damaged and foreign objects mixing in by covering them with a vinyl bag.
        Fig 6: Disconnecting Fuel Pipe By Pulling Connector
        G02639359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Observe the following when connecting the fuel tube connector (quick 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 into the connector until a "click" sound is heard. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe.
        Fig 7: Identifying Proper Fuel Pipe Installation (Matching Axis Of Connector)
        G02639360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After having finished the connection, pull the pipe and the connector to ensure secure connection.
      4. Check to make sure no fuel leak is present.

        If the result is not specified, repair or replace.

        Fig 8: Verifying Locked Connection By Pulling Connector
        G02639361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Install the fuel pipe clamp to the connector.
      6. Check to make sure no fuel leak is present.

        If the result is not specified, repair or replace.

        Fig 9: Installing Fuel Pipe Clamp
        G02639362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Observe the following when disconnecting the fuel tube connector (metallic type):

      HINT:

      The structure of the metallic connector is as shown.

      Fig 10: Disconnecting Fuel Tube Connector (Metallic Type)
      G02639363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check if there is any dirt like mud in the pipe and around the connector before disconnecting the fuel tube connector. If necessary, clean the dirt away.
      2. Assemble SST to the connection, as shown.

        SST 09268-21010

        Fig 11: Assembling SST To Fuel Pipe Connection
        G02639364Courtesy 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: Aligning Retainers Inside Connector With SST Chamfered Parts
        G02639365Courtesy 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 connector together towards the fuel tube assembly.
        Fig 13: Pulling Connector Towards SST
        G02639366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Observe the following 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 into the connector until a "click" sound is heard. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe.
        Fig 14: Matching Axis Of Connector With Axis Of Pipe & Pushing
        G02639367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. After having finished the connection, pull the pipe and the connector to ensure secure connection.
      4. Check to make sure no fuel leak is present.

      If the result is not specified, repair or replace.

      Fig 15: Verifying Locked Connection By Pulling Connector
      G02639368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Observer the following when handling the nylon tube:
      1. Pay attention not to turn the connected part of the nylon tube and the 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.
    9. Check that there is no fuel leak after doing maintenance anywhere on the fuel system.
      1. Connect the 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 ACTIVE TEST mode on the hand-held tester.
          Fig 16: Connecting Hand-Held Tester To DLC3
          G02639369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Do not start the engine.

        HINT:

        Please refer to the hand-held tester operator's manual for further details.

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

      2. Check that there is no leak from 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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