Content .. 86 87 88 89 ..

Toyota Corolla (2004+). Manual - part 88

11-32

FUEL

- FUEL TANK ASSY

36. INSTALL FUEL TANK ASSY

(a) Set a mission jack to the fuel tank.

(b) Install the fuel tank and 2 fuel tank bands with the 4 bolts.

Torque: 39 N m (400 kgf cm, 29 ft lbf)

37. CONNECT FUEL EMISSION TUBE SUB-ASSY NO.1

(a) Push in the fuel tube connector to the pipe until fuel tube connector makes ”click” sound.

NOTICE:

Check if there is any damage or foreign objects on the connected part.

After connecting, check if the fuel tube connector and pipe are securely connected by pulling

them.

38. CONNECT FUEL TANK MAIN TUBE SUB-ASSY

(a) Push in the fuel tube connector to pipe until fuel tube connector, and install the fuel tube connector

clip.

NOTICE:

Check if there is any damage or foreign objects on the connected part.

After connecting, check if the fuel tube connector and pipe are securely connected by pulling

them.

39. INSTALL PARKING BRAKE CABLE ASSY NO.3

(a) Install the parking brake cable with the 2 bolts.

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

40. INSTALL PARKING BRAKE CABLE ASSY NO.2

(a) Install the parking brake cable with the 2 bolts.

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

41. INSTALL FUEL TANK PROTECTOR NO.1

(a) Install the fuel tank protector with the 5 bolts.

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

42. INSTALL EXHAUST PIPE ASSY FRONT

(a) Using vernier calipers, measure the free length of the

compression spring.

Free length:

Wooden

Front side 43mm

(1.6929 in.)

Block

Rear side 40mm (1.5748 in.)

(b) Using a hammer and wooden block, tap in a new gasket

Gasket

until its surface is flush with the exhaust manifold.

A63953

NOTICE:

Tap in the gasket in the correct direction.

Do not reuse the removed gasket.

Be sure not to push in the gasket by installing the ex-

haust pipe.

11-33

FUEL

- FUEL TANK ASSY

(c)

Install a new gasket on the exhaust pipe (rear side).

(d) Install the exhaust pipe with the 4 compression springs

Tail Pipe Side

and 4 bolts.

Torque: 43 N m (440 kgf cm, 32 ft lbf)

(e) Install the 2 exhaust pipe supports.

(f)

Connect the oxygen sensor connector.

Gasket

(g) Install the font floor carpet with a clip.

A51891

43.

INSTALL FLOOR PANEL BRACE FRONT

(a)

Install the floor panel brace front with the 2 nuts.

Torque: 30 N m (302 kgf cm, 22 ft lbf)

44.

INSTALL FUEL SUCTION TUBE SET GASKET (See page

11-16)

45.

INSTALL FUEL PUMP ASSEMBLY (See page

11-16)

46.

INSTALL FUEL TANK VENT TUBE SET PLATE (See page

11-16)

47.

CONNECT FUEL EMISSION TUBE SUB-ASSY NO.1 (See page 11-16)

48.

CONNECT FUEL TANK MAIN TUBE SUB-ASSY (See page 11-16)

49.

CHECK FUEL LEAK (See page 11-1)

50.

CHECK EXHAUST GAS LEAK

51.

INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-16)

52.

INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (See page

72-6, 72-8)

11-7

FUEL

- FUEL SYSTEM

110FH-01

INSPECTION

FUEL INJECTOR ASSY

(a) Inspect injector resistance.

(1)

Using an ohmmeter,measure the resistance be-

tween the terminals.

Resistance: 13.4 - 14.2

W at 20_C (68_F)

A66088

(b) Inspect injector inspection

Fuel Tube Connector

CAUTION:

Keep injector clear of sparks during the test.

(1)

Purchase a new fuel tube, and take out the fuel tube

connector from its tube.

HINT:

Part No. 23901-0D010

A62159

(2)

Connect SST and fuel tube connector to the fuel

Fuel Tube Connector

pipe.

SST

09268-41047 (90467-13001, 95336-08070)

CAUTION:

SST (Hose)

Perform connecting operations of the fuel tube connector

(quick type) after observing the precautions.

SST (Clip)

A60555

(3)

Install an O-ring to the fuel injector.

SST (Hose)

(4)

Connect SST (union and hose) to fuel the injector,

SST

SST (Clip)

and hold the fuel injector to prevent gasoline from

(Adapter)

O-ring

splashing out. (See page 11-1)

SST

09268-41047 (90467-13001, 95336-08070,

SST

09268-41110, 09268-41300)

(Clamp)

Vinyl Tube

A62878

11-8

FUEL

- FUEL SYSTEM

(5)

Put the fuel injector into a graduated cylinder.

HINT:

Install a suitable vinyl tube onto the injector to prevent gasoline

SST

from splashing out.

(6)

Operate the fuel pump.

(7)

Connect SST to the connector of fuel injector.

SST

09842-30080

(8)

Connect SST to the battery for 15 seconds, and

A62879

measure the injection volume with a graduated cyl-

inder. Test the each fuel injector 2 or 3 time.

Injection volume:

60 - 73 cm 3 (3.7 - 4.5 cu in.) per 15 seconds

Difference between each injector:

13 cm 3 (0.8 cu in.) or less

(c)

Inspect leakage

(1)

In the condition above, disconnect the test probes

of the from the battery, and check the fuel leakage

from the fuel injector.

Fuel drop: 1 drop or less per 12 minutes

B00069

FUEL PUMP

(a) Inspect fuel pump resistance.

(1)

Using an ohmmeter, measure the resistance be-

tween the terminals.

Resistance: 0.2 - 3.0

W at 20_C (68_F)

(b) Inspect fuel pump operation

(1)

Apply battery voltage to both terminals. Check that

the pump operates.

A66089

NOTICE:

These tests must be done quickly (within 10 seconds)

to prevent the coil from burning out.

Keep fuel pump as far away from the battery as pos-

sible.

Always do the switching at the battery side.

11-5

FUEL

- FUEL SYSTEM

110FG-01

ON-VEHICLE INSPECTION

CHECK FUEL PUMP OPERATION

(a) Connect the hand-held tester to the DLC3.

2 1

(b) Turn the ignition switch ON and hand-held tester main

5 4

switch ON.

NOTICE:

Do not start the engine.

(c)

Select the active test mode on the hand-held tester.

(d) Please refer to the hand-held tester operator’s manual

A65704

for further details.

(e) If you have no hand-held tester, connect the positive (+)

lead form the battery to terminal 4 of the connecter, and

the negative (-) lead to terminal 5.

NOTICE:

These tests must be done quickly (within 10 seconds)

to prevent the coil burning out.

Keep the fuel pump as far away from the battery as

possible.

Always do the switching at the battery side.

CHECK FUEL PRESSURE

Fuel Tube Connector

(a) Prepare for inspection.

(1)

Purchase a new fuel tube, and take out the fuel tube

connector from its tube.

HINT:

Part No. 23901-0D010

(b) Work for prevent gasoline from spilling out.

(See page 11-1)

A62159

(c)

Disconnect the EFI fuel pipe clamp. (See page 11-1)

(d) Disconnect the fuel tube from the fuel main tube.

(See page 11-1)

11-6

FUEL

- FUEL SYSTEM

(e) Install SST (pressure gauge) as shown in the illustration

SST (Clip)

SST (Gauge)

by using the SST and fuel tube connector.

SST

09268-41047 (90467-13001, 95336-08070),

09268-45014 (09268-41200, 09268-41220,

09268-41250, 90467-13001)

(f)

Wipe off any splattered gasoline.

SST (T-joint)

(g) Start the engine.

(h) Measure the fuel pressure at idle.

Fuel Tube

Fuel pressure:

SST (Hose)

304 - 343 kPa (3.1 - 3.5 kgf cm 2, 44 - 50 psi)

(i)

Stop the engine.

(j)

Check that the fuel pressure remains as specified for 5

SST

minutes after the engine has stopped.

Fuel pressure:

147 kPa (1.5 kgf cm 2, 21 psi) or more

If pressure is not as specified, check the fuel pump, pressure

regulator and/or injectors.

SST (Hose)

(k)

After checking fuel pressure, disconnect the negative (-)

Fuel Tube Connector

A65093

terminal cable from the battery and carefully, remove the

SST and fuel tube connector to prevent gasoline from the

splashing.

(l)

Reconnect the fuel tube to fuel main tube.

(m) Install the EFI fuel pipe clamp.

(n) Check fuel leak. (See page 11-1)

11-1

FUEL

- FUEL SYSTEM

FUEL SYSTEM

110FF-01

PRECAUTION

BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM

BATTERY

DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM

KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS

WORK FOR PREVENT GASOLINE FROM SPILLING

OUT

(a)

Remove the rear seat cushion.

(See page 72-6, 72-8)

(b)

Remove rear floor service hole cover.

(See page 11-16)

(c)

Disconnect the fuel pump connector.

(d)

Start the engine. After the engine has stopped on its own,

A65618

turn the ignition switch to lock.

(e)

Disconnect negative (-) terminal cable from battery.

(f)

Connect the fuel pump connector.

(g)

Install rear floor service hole cover. (See page 11-16)

(h)

Install the rear seat cushion.

(See page 72-6, 72-8)

FUEL SYSTEM

(a)

When disconnecting the high fuel pressure line, a large

amount of gasoline will spill out, so observe these proce-

dures.

(1)

Work for prevent gasoline from spilling out.

(2)

Disconnect the fuel tank main tube.

(3)

Drain the fuel remained inside the fuel tank main

tube.

A62151

(4)

Protect the disconnected fuel tank main tube from

damage and foreign material by covering it with a vi-

nyl bag.

(5)

Put a container under the connection.

B07739

11-2

FUEL

- FUEL SYSTEM

(b) Observe these precautions when removing and installing

Correct

O-ring

the fuel injector.

(1)

Never reuse an O-ring.

(2)

When placing a new O-ring on the fuel injector, take

Injector

care not to damage it in any way.

Delivery Pipe

(3)

Coat a new O-ring with spindle oil or gasoline be-

Wrong

fore installing.

NOTICE:

A62152

Never use engine, gear or brake oil.

(c)

Install the fuel injector to the fuel delivery pipe and cylin-

Delivery Pipe

der head, as shown in the illustration. Before installing the

fuel injector, be sure to apply spindle oil or gasoline on the

place where the fuel delivery pipe touches an O-ring of

Insulator

the fuel injector.

O-ring

A65703

(d) Observe these precautions when disconnecting the fuel

delivery pipe.

O-ring

Retainer

Pipe

HINT:

The structure of the metallic connector is shown as illustration.

Nylon Tube

Housing

A62154

(1)

Remove the EFI fuel pipe clamp.

(2)

Get the metallic connector of the fuel tube assem-

bly, pull it out towards the rear and hold it as it is.

A65080

(3)

Assemble SST to the connection as shown.

SST

09268-21010

SST

A62165

11-3

FUEL

- FUEL SYSTEM

(4)

Turn SST, align the retainers inside the connector

with SST chamfered parts and insert SST into the

connector.

SST

(5)

Slide SST and the connector together towards the

fuel tube assembly.

Retainer

(at 4 places)

Insert

A62156

(e) Observe these precautions when disconnecting the fuel

tube connector (quick type).

(1)

Remove the EFI fuel pipe clamp.

(2)

Check if there is any dirt like mud on the pipe and

around the connector before disconnecting them

and clean the dirt away.

A65012

(3)

Be sure to disconnect with hands.

Push

(4)

When the connector and the pipe are stuck, pinch

the retainer between the hands, push and pull the

connector to free to disconnect and pull it out.

NOTICE:

Pull

Do not use any tool at this time.

(5)

Inspect if there is any dirt or the likes on the seal sur-

face of the disconnected pipe and clean it away.

A62157

(6)

Prevent the disconnected pipe and connector from

damaging and mixing foreign objects by covering

them with a vinyl bag.

B09222

(f)

Observe these precautions when connecting the fuel

tube connector (quick type).

(1)

Match the axis of the connector with axis of the pipe,

and push in the connector until retainer makes a

”click” sound. In case that the connections is tight,

apply little amount of new engine oil on the tip of the

pipe.

(2)

After having finished the connection, check if the

A56654

pipe and the connector are securely connected by

pulling them.

11-4

FUEL

- FUEL SYSTEM

CHECK FUEL LEAK

(a) Check that there are no fuel leaks after doing mainte-

2 1

nance anywhere on the fuel system.

5 4

(1)

Connect the hand-held tester to the DLC3.

(2)

Turn the ignition switch ON and hand-held tester

main switch ON.

(3)

Select the active test mode on the hand-held tester.

(4)

Please refer to the hand-held tester operator’s

A65704

manual for further details.

(5)

If you have no hand-held tester, connect the posi-

tive (+) and negative (-) leads from the battery to the

fuel pump connector.

(6)

Check that there are no leaks from any part of the

fuel system.

(7)

Turn the ignition switch to LOCK.

(8)

Disconnect the hand-held tester from the DLC3.

12-6

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

1204E-01

INSPECTION

CHARCOAL CANISTER ASSY

(a) Visually check the charcoal canister for cracks or dam-

age.

A63966

(b) Inspect the charcoal canister operation.

Purge Port

EVAP Port

(1)

Plug the vent port with the cap.

Vent Port

(2)

While holding the purge port closed, blow air (1.76

Air Drain Port

kPa, 18 gf/cm2, 0.26 psi) into the EVAP port and

check that air flows from the air drain port.

Cap

Air

A63968

(3)

While holding the purge port and the air drain port

Air Inlet Port

Purge Port

closed, blow air (1.76 kPa, 18 gf/cm2, 0.26 psi) into

EVAP Port

Air Drain Port

the EVAP port and check that air does not flow from

the air inlet port.

Air

A63970

(4)

Apply vaccum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg)

to the purge port, check that the vacuum dose not

Air Inlet

decrease when the air inlet port is closed, and

Port

check that the vacuum decreases when the air inlet

port is released.

Vacuum Purge Port

A63972

12-7

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

(5)

While holding the air inlet port closed, apply vacuum

Purge Port

Air Inlet

(3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port

Port

and check that air flows into the purge port.

If operation is not as spacified, replace the charcoal canister.

(6)

Remove the hose and cap from vent port.

Vacuum

EVAP Port

A65903

(c)

Inspect VSV for Pressure Swiching Valve

Ohmmeter

(1)

Using an ohmmeter, check that there is continuity

between the terminals.

Resistance: 37 - 44

W at 20FC (68FF)

If there is no continuity, replace the VSV.

Continuity

A65908

Ohmmeter

(2)

Using an ohmmeter, check that there is no continu-

ity between each terminal and the body.

If there is continuity, replace the VSV.

No Continuity

A65909

(3)

Check that air does not flow from ports E to F.

Air

A65910

(4)

Apply battery positive voltage across the terminals.

(5)

Check that air flows from ports E to F.

If operation is not as specified, replace the VSV.

Battery

Air

A65911

12-8

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

VENTILATION VALVE SUB-ASSY

Cylinder Head Side

(a) Install clean hose to the PCV valve.

(b) Inspect the PCV valve operation.

Clean Hose

(1)

Blow air into the cylinder head side, and check that

air passes through easily.

CAUTION:

Do not suck air through the valve. Petroleum substances

inside the valve air harmful.

P11834

(2)

Blow air into the intake manifold side, and check

Intake Manifold Side

that air passes through with difficulty.

If operation is not as specified, replace the PCV valve.

(c)

Remove clean hose from the PCV valve.

P11831

FUEL TANK CAP ASSY

(a) Visually check if cap and/or gasket are deformed or dam-

aged.

If necessary, repair or replace the cap.

Gasket

B11870

VACUUM SWITCHING VALVE NO.1

Ohmmeter

(a) Inspect VSV for evaporative emission (EVAP).

(1)

Using an ohmmeter, check that there is continuity

between the terminals.

Resistance: 27 - 33

W at 20FC (68FF)

If there is no continuity, replace the VSV.

Continuity

A65912

(2)

Using an ohmmeter, check that there is no continu-

Ohmmeter

ity between each terminal and the body.

If there is continuity, replace the VSV.

No Continuity

A65913

12-9

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

(3)

Check that air flows from ports E to F.

Air

A65914

(4)

Apply battery positive voltage across the terminals.

(5)

Check that air does not flow from ports E to F.

Air

If operation is not as specified, replace the VSV.

Battery

A65915

VACUUM SWITCHING VALVE ASSY NO.1

Ohmmeter

Continuity

(a) Inspect VSV for Canister Closed valve (CCV).

(1)

Using an ohmmeter, check that there is continuity

between the terminals.

Resistance: 25 - 30

W at 20FC (68FF)

If there is no continuity, replace the VSV.

A65916

(2)

Using an ohmmeter, check that there is no continu-

Ohmmeter

No Continuity

ity between each terminal and the body.

If there is continuity, replace the VSV.

A65917

(3)

Check that air flows from ports A to B.

Air

A65918

12-10

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

(4)

Apply battery positive voltage across the terminals.

(5)

Check that air does not flow from ports A to B.

If operation is not as specified, replace the VSV.

Air

Battery

A65919

Content .. 86 87 88 89 ..