Toyota Camry 2007-2009 Service Manual - 2AZ-FE_Fuel

2AZ-FE FUEL – FUEL SYSTEM

FUEL SYSTEM

PRECAUTION

1. PRECAUTION

(a) Before inspecting and repairing the fuel system,

disconnect the negative (-) battery terminal.

(b) Do not smoke or work near fire when handling the

fuel system.

2. DISCHARGE FUEL SYSTEM PRESSURE CAUTION:

• Perform the following procedures to prevent fuel

from spilling out before removing any fuel system parts.

• Pressure will still remain in the fuel line even after

performing the following procedures. When disconnecting the fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out.

(a) Disconnect the fuel pump connector.

(1) Remove the rear seat cushion assembly. (2) Remove the rear floor service hole cover. (3) Disconnect the fuel pump connector. (4) Start the engine. (5) After the engine stops, turn the ignition switch

off. HINT: DTC P0171/25 (fuel problem) and/or P0191/49

A129607

3. FUEL SYSTEM

(a) When disconnecting the high fuel pressure line, a

(fuel pressure sensor signal error) may be detected.

(6) Crank the engine again. Check that the engine

does not start.

(7) Remove the fuel tank cap to discharge pressure

from the fuel tank. (8) Disconnect the negative (-) battery terminal. (9) Reconnect the fuel pump connector. (10)Install the rear floor service hole cover. (11)Install the rear seat.

large amount of gasoline will spill out, so observe the following procedures: (1) Discharge the fuel system pressure. (step 2) (2) Disconnect the fuel pump tube (See page FU-

23).

(3) Drain the fuel that remains inside the fuel pump

tube.

FU–1

FU–2

Plastic Bag

CORRECT

INCORRECT

2AZ-FE FUEL – FUEL SYSTEM

(4) To protect the disconnected fuel pump tu be from

damage and contamination, cover it with a plastic bag.

(5) Put a container under the connection part.

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(b) Observe the following precautions when removing

and installing the fuel injectors: (1) Never reuse an O-ring. (2) When placing a new O-ring on the injector, do

not damage the O-ring.

(3) Coat a new O-ring with gasoline before installing

it.

NOTICE: Do not use engine oil, gear oil or brake fluid.

O-Ring

Fuel Injector

Insulator

Delivery Pipe

O-Ring

O-ring

Fuel Delivery Pipe

Retainer

Pipe

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head, as shown in the illustration.

NOTICE: Before installing the injector, be sure to apply grease or gasoline to the place where the delivery pipe or cylinder head contacts the Oring of the injector.

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(d) Observe the following precautions when

disconnecting the fuel delivery pipe (metallic type): HINT: The structure of the metallic connector is shown on the left.

Nylon Tube

Housing

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Fuel Pipe

Retainer

(at 4 places)

2AZ-FE FUEL – FUEL SYSTEM

(1) Remove the No. 2 fuel pipe clamp.

HINT:

The No. 2 fuel pipe clamp cannot be reused.

A136248E01

(2) Find the metallic connector of the fuel tube

assembly. (3) Assemble SST to the connection as shown in

the illustration.

SST 09268-21010

(4) Turn the SST, align the retainers inside the

connector with the SST chamfered parts and

insert SST into the connector. (5) Slide the SST and the connector together

towards the fuel tube assembly.

FU–3

SST

Push

A130371E01

(e) Observe the following precautions when connecting

the fuel tube connector (metallic type): (1) Check if there is any damage or foreign objects

on the connecting part of the pipe. (2) Match the axis of the connector with the axis of

the pipe, and push into the connector until the

connector makes a "click" sound. If the

connection is tight, apply a small amount of fresh

engine oil to the tip of the pipe.

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(3) After finishing the connection, check if the pipe

and the connector are securely connected by

pulling on them. (4) Check for fuel leaks.

Pull

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FU–4

No. 1 Fuel Pipe Clamp

2AZ-FE FUEL – FUEL SYSTEM

(5) Install a new No. 2 fuel pipe clamp.

Fuel Pipe

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(f) Observe the following precautions when

disconnecting the fuel tube connectors (Quick type A): (1) Remove the No. 1 fuel pipe clamp from the tube

connector.

(2) Check that there is no dirt or other foreign

objects on the pipe and around the connector before disconnecting them. Clean them if necessary.

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Quick Type A

(3) Disconnect the connector from the pipe by hand. (4) When the connector and the pipe are stuck,

push in and pull on the connector to release it. Pull the connector out of the pipe carefully.

(5) Check that there is no dirt or other foreign

objects on the sealing surface of the disconnected pipe. Clean it away if necessary.

A088336E10

(6) Do not damage the disconnected pipe and

connector, and prevent entry of foreign objects by covering them with a plastic bag.

Plastic Bag

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2AZ-FE FUEL – FUEL SYSTEM

FU–5

Quick Type A

Push

Quick Type B

Pull

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(g) Observe the following precautions when connecting

the fuel tube connectors (Quick Type A): (1) Check if there is any damage or foreign objects

on the connecting parts of the pipes. (2) Line up the two parts of the pipes to be

connected, and push them together until the

connector makes a "click" sound. If the pipe is

difficult to push into the connector, apply a small

amount of clean engine oil to the tip of the pipe

and reinsert it. (3) After connecting the pipes, check that the pipe

and connector are securely connected by pulling

on them. (4) Check for fuel leaks.

(h) Observe the following precautions when

disconnecting the fuel tube connector (Quick type B): (1) Before disconnecting the connector, clean off

any dirt that may be present. (2) Pinch the tabs of the fuel tube retainer to

disengage the 2 claws. Push the retainer down

as shown in the illustration.

HINT:

Be sure to disconnect the connector by hand.

Quick Type B

Plastic Bag

(3) If the connector and pipe are stuck, hold the fuel

pipe by hand and push and pull on the

connector. Pull the two pipes apart to separate

the connector. (4) If there is any dirt or any other foreign objects on

the sealing surfaces of the disconnected pipes,

clean them if necessary.

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(5) Do not damage the disconnected pipe and

connector, and prevent entry of foreign objects

by covering them with a plastic bag.

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FU–6

2AZ-FE FUEL – FUEL SYSTEM

Quick Type B

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(i) Observe the following precautions when connecting

the fuel tube connector (Quick Type B): (1) Line up the two parts of the pipes to be

connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push in to the connector , apply a small amount of clean engine oil to the tip of the pipe and reinsert it.

(2) After connecting the pipes, check that the pipe

and connector are securely connected by pulling on them.

(3) Check for fuel leaks.

(j) Observe the following precautions when handling a

nylon tube:

CAUTION:

• Do not twist the connection part of the nylon tube and the quick connector when connecting them.

• Do not bend or twist the nylon tube.

• Do not remove the EPDM protector on the outside of the nylon tube.

• Do not close the piping by bending the nylon tube.

4. CHECK FOR FUEL LEAKS

(a) Check that there are no fuel leaks from the fuel

system after doing any maintenance or repairs (See page FU-9).

PARTS LOCATION

2AZ-FE FUEL – FUEL SYSTEM

FU–7

ECM

FUEL PUMP

ENGINE ROOM RELAY BLOCK

FUEL INJECTOR

A136012E01

FU–8

INJ

E23 Ignition Switch

IG2

AM2

ST/AM2

From Battery

2AZ-FE FUEL – FUEL SYSTEM

SYSTEM DIAGRAM

C7 Fuel Injector (No. 1)

C9 Fuel Injector (No. 2)

C8 Fuel Injector (No. 3)

108

C24

107

C24

106

C24

ECM

#10

#20

#30

EFI MAIN

From Battery

N10 Fuel Suction Pump and Gauge Assembly

Pump

C10 Fuel Injector (No. 4)

EFI

C/OPN

105

C24

A24

#40

MREL

IGN

A24

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2AZ-FE FUEL – FUEL SYSTEM

ON-VEHICLE INSPECTION

1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAKS

(a) Check fuel pump operation.

(1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position and

push the intelligent tester main switch on.

NOTICE: Do not start the engine.

(3) Select the following menu items: DIAGNOSIS /

ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.

(4) Check for pressure in the fuel inlet tube from

the fuel line. Check that sound of fuel flowing in the fuel tank can be heard. If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.

(b) Check for fuel leaks.

(1) Check that there are no fuel leaks anywhere on

the system after performing maintenance. If there is a fuel leak, repair or replace parts as

necessary. (c) Turn the ignition switch off. (d) Disconnect the intelligent tester from the DLC3.

FU–9

No. 1 Fuel Pipe Clamp

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2. CHECK FUEL PRESSURE

(a) Using a voltmeter, measure the battery voltage.

Standard voltage:

11 to 14 V

(b) Discharge the fuel system pressure (See page FU-

1).

terminal.

(d) Remove the No. 1 fuel pipe clamp from the fuel tube

connector.

(e) Disconnect the fuel hose from the fuel main tube.

CAUTION:

• Always read the precautions (See page FU-1) 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.

FU–10

2AZ-FE FUEL – FUEL SYSTEM

SST (Clip)

SST (T-joint)

SST (Tube)

SST (Hose)

SST (Tube Connector)

SST (Pressure Gauge)

A105669E04

(f) Install SST (pressure gauge) and the fuel tube

connector using SST as shown in the illustration.

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

95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250)

(g) Wipe up any gasoline. (h) Reconnect the cable to the negative (-) battery

terminal.

(i) Select the following menu items: DIAGNOSIS /

ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.

(j) Measure the fuel pressure.

Fuel pressure:

304 to 343 kPa (3.1 to 3.5 kgf/cm

, 44.1 to 49.7

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. (k) Disconnect the intelligent tester from the DLC3. (l) Start the engine. (m) Measure the fuel pressure at idle.

Fuel pressure:

304 to 343 kPa (3.1 to 3.5 kgf/cm

, 44.1 to 49.7

psi)

(n) 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/cm

, 21 psi) or more

If the pressure is not as specified, check the fuel

pump, pressure regulator and/or injectors. (p) After checking the fuel pressure, disconnect the

cable from the negative battery terminal and

carefully remove the SST to prevent gasoline from

splashing. (q) Reconnect the fuel main tube (fuel tube connector).

CAUTION:

Always read the precautions (See page FU-1)

before connecting the fuel tube connector

(quick type).

(r) Install the No. 1 fuel pipe clamp to the fuel tube

connector. (s) Check for fuel leaks (Step 1).

ENGINE2AZ-FE FUEL

FUEL INJECTOR

COMPONENTS

AIR CLEANER CAP SUB-ASSEMBLY

ENGINE WIRE

FUEL DELIVERY PIPE WITH INJECTOR

2AZ-FE FUEL – FUEL INJECTOR

NO. 2 VENTILATION HOSE

20 (204, 15)

FU–11

PURGE VSV VACUUM HOSE

SPACER

O-RING

NO. 2 VENTILATION HOSE

INSULATOR

7.0 (71, 62 in.*lbf)

PURGE VSV VACUUM HOSE

FUEL INJECTOR ASSEMBLY

NO. 1 FUEL PIPE CLAMP

NO. 1 ENGINE COVER SUB-ASSEMBLY

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

Non-reusable part

: Specified torque

A136019E01

FU–12

2AZ-FE FUEL – FUEL INJECTOR

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

HINT: See page FU-1.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416)

4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94)

5. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the No. 1 fuel pipe clamp.

NOTICE: Check for foreign matter on the pipe and around the connector before disconnecting the quick connector. Clean the connector if necessary.

Pinch

Pull

Pinch

A136015E01

(b) If the connector and pipe are stuck, pinch the

connector, and pu sh and pu ll the p ipe to disco nnect them.

NOTICE:

• Do not use any tools in this procedure.

• Check for foreign matter on the sealing surface of the disconnected pipe. Clean it if necessary.

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A136017E01

2AZ-FE FUEL – FUEL INJECTOR

6. DISCONNECT NO. 2 VENTILATION HOSE

(a) Disconnect the No. 2 ventilation hose from the

ventilation valve.

A097786

7. REMOVE FUEL DELIVERY PIPE WITH INJECTOR

(a) Remove the 2 wire harness clamps. (b) Disconnect the 4 fuel injector connectors.

FU–13

A136750

A136751

A128737

pipe together with the 4 fuel injectors.

NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

(d) Remove the 2 delivery pipe spacers from the

cylinder head.

(e) Remove the 4 insulators from the cylinder head.

Pull Out

8. REMOVE FUEL INJECTOR ASSEMBLY

(a) Pull out the 4 injectors from the delivery pipe. (b) Remove the 4 O-rings from the injectors.

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