2AZ-FE FUEL – FUEL SYSTEM FU–1

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.
(c) Keep gasoline away from rubber or leather parts.
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.
FU
(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 (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.
3. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a
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–2 2AZ-FE FUEL – FUEL SYSTEM

(4) To protect the disconnected fuel pump tube from

damage and contamination, cover it with a
plastic bag.
(5) Put a container under the connection part.

Plastic Bag

B000679E07

(b) Observe the following precautions when removing

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

O-Ring
Delivery Pipe

A131629E01

(c) Install the injector to the delivery pipe and cylinder

O-Ring head, as shown in the illustration.
NOTICE:
Before installing the injector, be sure to apply
Fuel Injector grease or gasoline to the place where the
delivery pipe or cylinder head contacts the O-
Insulator ring of the injector.
Fuel Delivery Pipe

A097444E02

(d) Observe the following precautions when

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

Nylon Tube Housing

A050709E01
 2AZ-FE FUEL – FUEL SYSTEM FU–3

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

HINT:
The No. 2 fuel pipe clamp cannot be reused.

Fuel Pipe

A136248E01

(2) Find the metallic connector of the fuel tube

Retainer assembly.
(3) Assemble SST to the connection as shown in
(at 4 places) 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

SST

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
Push engine oil to the tip of the pipe.
B084645E01

(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
B084645E04
 FU–4 2AZ-FE FUEL – FUEL SYSTEM

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

Fuel Pipe

A136248E02

(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.
No. 1 Fuel (2) Check that there is no dirt or other foreign
Pipe Clamp objects on the pipe and around the connector
before disconnecting them. Clean them if
necessary.
FU A060083E16

(3) Disconnect the connector from the pipe by hand.

Quick Type A
(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

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

Plastic Bag
B009222E04
 2AZ-FE FUEL – FUEL SYSTEM FU–5

(g) Observe the following precautions when connecting

Quick Type A 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
Push 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.

Pull

A121423E01 FU
(h) Observe the following precautions when
Quick Type B
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:
A129459E01 Be sure to disconnect the connector by hand.

(3) If the connector and pipe are stuck, hold the fuel
Quick Type B 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.

A091246E06

(5) Do not damage the disconnected pipe and

Quick Type B
connector, and prevent entry of foreign objects
Plastic Bag by covering them with a plastic bag.

A093309E03
 FU–6 2AZ-FE FUEL – FUEL SYSTEM

(i) Observe the following precautions when connecting

Quick Type B
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
A132390E01 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.
FU • 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).
 2AZ-FE FUEL – FUEL SYSTEM FU–7

PARTS LOCATION

FU
FUEL PUMP

ECM ENGINE ROOM RELAY BLOCK

FUEL INJECTOR

A136012E01
 FU–8 2AZ-FE FUEL – FUEL SYSTEM

SYSTEM DIAGRAM
ECM
C7 Fuel Injector (No. 1)
INJ
108
C24 #10
1 2

C9 Fuel Injector (No. 2)

E23 Ignition Switch
107
C24 #20
1 2

6 IG2 AM2 5

C8 Fuel Injector (No. 3)

106
ST/AM2 C24 #30
1 2
From
Battery

FU C10 Fuel Injector (No. 4)

105
C24 #40
1 2

EFI MAIN
From
Battery

EFI

44
A24 MREL

N10 Fuel Suction Pump and Gauge Assembly

5 4 C/OPN
Pump

IGN
7
A24 FC

A136724E01
 2AZ-FE FUEL – FUEL SYSTEM FU–9

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
FU
necessary.
(c) Turn the ignition switch off.
(d) Disconnect the intelligent tester from the DLC3.
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).
(c) Disconnect the cable from the negative (-) battery
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)
No. 1 Fuel before disconnecting the fuel tube connector
Pipe Clamp (quick type).
• The fuel pipe line may spray fuel as a result of
retained pressure that remains in it. Do not
A060083E16 allow fuel to be sprayed in the engine
compartment.
 FU–10 2AZ-FE FUEL – FUEL SYSTEM

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

SST (Clip) SST (Pressure
Gauge)
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)
SST (T-joint)
(g) Wipe up any gasoline.
(h) Reconnect the cable to the negative (-) battery
terminal.
SST (Tube) (i) Select the following menu items: DIAGNOSIS /
ENHANCED OBD II / ACTIVE TEST / FUEL PUMP
/ SPD.
(j) Measure the fuel pressure.
SST Fuel pressure:
(Hose)
304 to 343 kPa (3.1 to 3.5 kgf/cm2, 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
SST (Tube Connector) regulator.
FU A105669E04 (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/cm2, 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/cm2, 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).
 2AZ-FE FUEL – FUEL INJECTOR FU–11

FUEL INJECTOR
2AZ-FE FUEL
ENGINE

COMPONENTS

PURGE VSV
NO. 2 VENTILATION HOSE VACUUM HOSE

AIR CLEANER CAP SUB-ASSEMBLY

ENGINE WIRE

FUEL DELIVERY PIPE

WITH INJECTOR
20 (204, 15)

FU
SPACER

PURGE VSV VACUUM HOSE

O-RING

FUEL INJECTOR
INSULATOR ASSEMBLY

7.0 (71, 62 in.*lbf)

NO. 2 VENTILATION NO. 1 FUEL PIPE CLAMP

HOSE
NO. 1 ENGINE COVER SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
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.

FU
A136015E01

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

Pull connector, and push and pull the pipe to disconnect
them.
Pinch NOTICE:
• Do not use any tools in this procedure.
• Check for foreign matter on the sealing
Pinch
surface of the disconnected pipe. Clean it if
necessary.

A136016E01

(c) Separate the fuel tube from the fuel hose clamp.

A136017E01
 2AZ-FE FUEL – FUEL INJECTOR FU–13

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.

A136750
FU
(c) Remove the 2 bolts, then remove the fuel delivery
pipe together with the 4 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when
removing the fuel delivery pipe.

A136751

(d) Remove the 2 delivery pipe spacers from the

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

A128737

8. REMOVE FUEL INJECTOR ASSEMBLY

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

Pull Out

A097399E02
 FU–14 2AZ-FE FUEL – FUEL INJECTOR

Ohmmeter INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(a) Measure the resistance between the injector
terminals.
Standard resistance:
11.6 to 12.4 Ω at 20°C (68°F)
If the result is not as specified, replace the injector.
(b) Inspect the injector injection volume.
A116182E01
CAUTION:
Keep the injector away from sparks during this
test.
(1) Connect SST (fuel tube connector) to SST
Fuel Tube (hose), then connect them to the fuel pipe
SST (Clip)
(vehicle side).
SST 09268-31011 (09268-41500, 90467-
13001, 95336-08070)
(2) Install the O-ring to the fuel injector.

SST (Tube Connector)

FU SST (Hose)
A088228E08

(3) Connect SST (adapter and hose) to the

SST injector, and hold the injector and union with
SST
SST (clamp).
SST 09268-31011 (09268-41110, 09268-
41300, 90467-13001)
(4) Put the injector into the graduated cylinder.
CAUTION:
Install a suitable vinyl tube onto the injector
Tube to contain gasoline spray.
A116183E02 (5) Operate the fuel pump.

(6) Connect SST (wire) to the injector and the

battery for 15 seconds, and measure the
injection volume with the graduated cylinder.
Test each injector 2 or 3 times.
SST 09842-30080
SST Standard injection volume:
(Wire)
Connect 76 to 92 cm3 (4.6 to 5.6 cu in.) per 15
seconds
Standard difference between each injector:
16 cm3 (0.98 cu in.) or less
A075915E04
 2AZ-FE FUEL – FUEL INJECTOR FU–15

(c) Inspect the fuel leakage.

(1) Disconnect the SST (wire) tester probes from
the battery and check the fuel leakage from the
injector.
Standard fuel drop:
1 drop or less per 12 minutes
(2) Turn the ignition switch off.
(3) Disconnect the cable from the negative (-)
battery terminal.
A116184 (4) Remove the SST.
(5) Disconnect the intelligent tester from the DLC3.
(6) Reconnect the fuel inlet hose (rear fuel pipe) to
the fuel main tube.
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to new O-
rings, then install one onto each fuel injector.

FU
New O-Ring
A097400E02

(b) Apply a light coat of gasoline or spindle oil to the

CORRECT part of the fuel delivery pipe which comes into
contact with the O-ring of the fuel injector.
(c) Apply a light coat of gasoline or spindle oil to the O-
ring again, then install the right and left fuel injectors
onto the fuel delivery pipe.
NOTICE:
INCORRECT Make sure that the O-ring is not cracked or
jammed before installing the injector.
(d) Check that the fuel injector rotates smoothly. If the
fuel injector does not rotate, replace the O-ring.

O-Ring
Delivery Pipe

A131629E01

2. INSTALL FUEL DELIVERY PIPE WITH INJECTOR

(a) Install 4 new insulators into the cylinder head.
(b) Install the 2 delivery pipe spacers onto the cylinder
head.

A128737
 FU–16 2AZ-FE FUEL – FUEL INJECTOR

(c) Install the fuel delivery pipe together with the 4 fuel
O-Ring injectors, then temporarily tighten the 2 bolts.
NOTICE:
Be careful not to drop the fuel injectors when
Fuel Injector installing the fuel delivery pipe.
(d) Check that the fuel injector rotates smoothly.
Insulator If the fuel injector does not rotate smoothly, replace
Fuel Delivery Pipe
the O-ring.

A097444E02

(e) Tighten the 2 bolts to the specified torque.

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

FU A136751

(f) Connect the 4 fuel injector connectors.

(g) Install the 2 wire harness clamps.

A136750

3. INSTALL NO. 2 VENTILATION HOSE

White Paint Mark UP (a) Connect the ventilation hose to the ventilation valve.
“A” NOTICE:
LH Make sure that the paint mark and hose clamp
are positioned as shown in the illustration after
View: “A” connecting the hose.

A095428E03

4. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Install the fuel tube to the fuel hose clamp.

A136017E01
 2AZ-FE FUEL – FUEL INJECTOR FU–17

(b) Push the fuel tube connector until it makes a "click"

sound.
Push

A103968E03

(c) Install the No. 1 fuel pipe clamp.

5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-419)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. CHECK FOR FUEL LEAKS
HINT:
See page FU-9.
A136015E01

8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

FU
(See page EM-121)
 FU–18 2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPER

FUEL PRESSURE PULSATION DAMPER

2AZ-FE FUEL
ENGINE

COMPONENTS

NO. 1 ENGINE COVER SUB-ASSEMBLY

9.0 (92, 80 in.*lbf) PURGE VSV VACUUM HOSE

AIR CLEANER CAP SUB-ASSEMBLY

NO. 2 VENTILATION HOSE

NO. 2 FUEL PIPE CLAMP

FUEL PRESSURE PULSATION DAMPER ASSEMBLY

FU

AIR CLEANER
FILTER ELEMENT PURGE VSV
9.0 (92, 80 in.*lbf) VACUUM HOSE

FUEL TUBE SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

A141106E01
 2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPER FU–19

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
(See page EM-94)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-416)
5. DISCONNECT FUEL TUBE SUB-ASSEMBLY
HINT:
Disconnect the metallic type connector (See page FU-1).
6. REMOVE FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Remove the 2 bolts and fuel pressure pulsation
damper.
FU

A125338

INSTALLATION
O-Ring
1. INSTALL FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to the O-
ring of the fuel pressure pulsation damper.

A125339E01

(b) Install the fuel pressure pulsation damper with the 2

bolts.
Torque: 9.0 N*m (90 kgf*cm, 80 in.*lbf)
NOTICE:
Make sure that the O-ring is not cracked or
jammed before installing the damper.
2. INSTALL FUEL TUBE SUB-ASSEMBLY
HINT:
Connect the metallic type connector (See page FU-1).
A125338

3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See

page ES-419)
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
 FU–20 2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPER

5. CHECK FOR FUEL LEAKS

HINT:
See page FU-9.
6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
(See page EM-121)

FU
 2AZ-FE FUEL – FUEL PUMP FU–21

FUEL PUMP
2AZ-FE FUEL
ENGINE

COMPONENTS

REAR SEAT CUSHION ASSEMBLY

FU

REAR FLOOR SERVICE HOLE COVER

FUEL PUMP TUBE SUB-ASSEMBLY

CLIP
5.9 (60, 52 in.*lbf)
x8

FUEL TANK VENT TUBE SET PLATE

FUEL SUCTION TUBE ASSEMBLY

WITH PUMP AND GAUGE

GASKET

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
A136244E01
 FU–22 2AZ-FE FUEL – FUEL PUMP

FUEL NO. 1 SUCTION SUPPORT

FUEL SUCTION PLATE SUB-ASSEMBLY

SPRING
FU
O-RING FUEL PUMP HARNESS

E-RING
O-RING

FUEL PRESSURE REGULATOR ASSEMBLY

FUEL PUMP

FUEL NO. 1 TANK BAND BRACKET

FUEL SENDER GAUGE ASSEMBLY

Non-reusable part
A136245E01
 2AZ-FE FUEL – FUEL PUMP FU–23

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY (for
Fixed Seat Type) (See page SE-77)
4. REMOVE REAR SEAT CUSHION ASSEMBLY (for
Fold Down Seat Type) (See page SE-47)
5. REMOVE REAR SEAT CUSHION ASSEMBLY (for
Reclining Seat Type) (See page SE-62)
6. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the rear floor service hole cover.
(b) Disconnect the fuel pump connector.

FU

A129478

7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY

Tube Joint Clip (a) Remove the tube joint clip, and pull out the fuel
pump tube.
NOTICE:
• Check that there is no dirt around the fuel
tube joint before this work and clean any dirt
away.
• It is necessary to prevent mud or dirt from
entering the fuel tube joint. If mud enters the
joint, the O-rings may not seal the fuel tube
connector and fuel suction plate properly.
Nylon Tube • Do not use any tools in this work.
• Do not bend or twist the nylon tube.
Fuel Tube Joint • After disconnecting, cover the fuel tube joint
with a plastic bag.
• If the fuel tube joint and fuel suction plate are
stuck, pinch the fuel tank tube between
O-Ring fingers, and turn it carefully to release.
Tube Joint Clip
Disconnect the fuel tank tube.

A129479E02
 FU–24 2AZ-FE FUEL – FUEL PUMP

8. REMOVE FUEL TANK VENT TUBE SET PLATE

(a) Remove the 8 bolts and set plate.

A129480

9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH

PUMP AND GAUGE
(a) Pull out the fuel suction tube from the fuel tank.
NOTICE:
• Do not damage the fuel pump filter.
• Be careful that the arm of the sender gauge
does not bend.

FU A139190

(b) Remove the gasket from the fuel suction tube.

Gasket

A136023E01

DISASSEMBLY
1. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Disconnect the fuel sender gauge connector.

A136021
 2AZ-FE FUEL – FUEL PUMP FU–25

(b) Unlock the fuel sender gauge, and slide it to

remove.

A136022

2. REMOVE FUEL NO. 1 TANK BAND BRACKET

(a) Using needle nozzle pliers, remove the E-ring.

FU

E-Ring
A136234E01

(b) Disengage the 4 claws of the fuel No. 1 suction

support and remove the fuel No. 1 tank band
bracket from the fuel suction plate with the fuel filter.
(c) Remove the spring from the fuel suction plate.

A136232

3. REMOVE FUEL NO. 1 SUCTION SUPPORT

(a) Using a screwdriver with the tip taped, disengage
the claw and remove the fuel No. 1 suction support.

A136233
 FU–26 2AZ-FE FUEL – FUEL PUMP

4. DISCONNECT FUEL PUMP HARNESS

(a) Disconnect the fuel pump harness connector from
the fuel suction plate.

A136231

5. REMOVE FUEL PUMP

(a) Using a screwdriver with its tip taped, disengage the
5 claws and pull out the fuel pump from the fuel filter
assembly.
NOTICE:
• Do not damage the fuel pump filter.
• Do not remove the suction filter.

FU

A136239E01

(b) Remove the fuel pump harness connector.

A136237

(c) Remove the O-ring from the fuel pump.

O-Ring

A136238E01
 2AZ-FE FUEL – FUEL PUMP FU–27

6. REMOVE FUEL PRESSURE REGULATOR

ASSEMBLY
(a) Using a screwdriver with its tip taped, remove the
fuel pressure regulator from the fuel filter.

A136235

(b) Remove the 2 O-rings from the fuel pressure

O-Ring regulator.

A096585E03
FU
INSPECTION
1. INSPECT FUEL PUMP
(a) Check the fuel pump resistance.
(1) Measure the resistance between terminals 1
and 2.
Standard resistance:
0.2 to 3.0 Ω at 20°C (68°F)
If the result is not as specified, replace the fuel
A126943
pump.
(b) Check fuel pump operation.
(1) Apply battery voltage to terminals 1 and 2.
Check that the pump operates.
NOTICE:
• These tests must be completed within 10
seconds to prevent the coil from burning
out.
• Keep the fuel pump as far away from the
battery as possible.
• Always switch the voltage on and off on
the battery side, not on the fuel pump
side.
If the pump does not operate, replace the fuel
pump.
 FU–28 2AZ-FE FUEL – FUEL PUMP

O-Ring REASSEMBLY
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
(a) Apply a light coat of gasoline to 2 new O-rings, and
install them to the fuel pressure regulator.

A096585E03

(b) Install the fuel pressure regulator to the fuel filter.

Pressure Regulator

FU A136236E01

2. INSTALL FUEL PUMP

(a) Apply gasoline to a new O-ring and install it to the
fuel filter.
New O-Ring

A131633E01

(b) Connect the fuel pump harness connector.

A126130
 2AZ-FE FUEL – FUEL PUMP FU–29

(c) Engage the 5 claws on the fuel filter and install the
fuel pump with the pump filter.

A136240

3. CONNECT FUEL PUMP HARNESS

(a) Connect the fuel pump harness connector from the
fuel suction plate.
FU

A136231

4. INSTALL FUEL NO. 1 SUCTION SUPPORT

(a) Install the fuel No. 1 suction support to the fuel filter.
5. INSTALL FUEL NO. 1 TANK BAND BRACKET
(a) Install the spring to the fuel suction plate shaft and
install them to the fuel No. 1 tank band bracket.
(b) Engage the 4 claws of the fuel No. 1 suction support
and install the fuel No. 1 tank band bracket to the
fuel suction plate with the fuel filter.
A136233

(c) Install a new E-ring.

E-Ring
A136234E01
 FU–30 2AZ-FE FUEL – FUEL PUMP

6. INSTALL FUEL SENDER GAUGE ASSEMBLY

(a) Slide the fuel sender gauge to engage the claw.

A136241

(b) Connect the fuel sender gauge connector.

FU

A136021

INSTALLATION
1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH
Gasket PUMP AND GAUGE
(a) Install a new gasket to the fuel suction tube.

A136023E01

(b) Install the fuel suction tube.

NOTICE:
• Do not damage the fuel pump filter.
• Be careful that the arm of the sender gauge
does not bend.

A139190
 2AZ-FE FUEL – FUEL PUMP FU–31

2. INSTALL FUEL TANK VENT TUBE SET PLATE

(a) Align the mark of the set plate with the fuel suction
tube.
(b) Install the set plate with the 8 bolts.
Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)

Mark
A129480E01

3. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY

(a) Install the fuel pump tube with the tube joint clip.
NOTICE:
• Check that there are no scratches or foreign
objects on the connecting part.
• Check that the fuel tube joint is inserted
securely.
• Check that the tube joint clip is on the collar
of the fuel tube joint.
Fuel Main Tube • After installing the tube joint clip, check that FU
Fuel Tube Joint the fuel tube joint is pulled off.
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL

Fuel Tube 5. CHECK FOR FUEL LEAKS (See page FU-8)

O-Ring

Tube Joint Clip

Tube Joint Clip

Collars

Collars
CORRECT INCORRECT
A139189E01

6. INSTALL REAR FLOOR SERVICE HOLE COVER

(a) Connect the fuel pump connector.
(b) Install the rear floor service hole cover with new
butyl tape.
7. INSTALL REAR SEAT CUSHION ASSEMBLY (for
Fixed Seat Type) (See page SE-84)
8. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold
Down Seat Type) (See page SE-58)
A129478
9. INSTALL REAR SEAT CUSHION ASSEMBLY (for
Reclining Seat Type) (See page SE-73)
 FU–32 2AZ-FE FUEL – FUEL TANK

FUEL TANK
2AZ-FE FUEL
ENGINE

COMPONENTS

REAR SEAT CUSHION ASSEMBLY

FU

REAR FLOOR SERVICE HOLE COVER

FUEL PUMP TUBE SUB-ASSEMBLY

CLIP
5.9 (60, 52 in.*lbf)
x8

FUEL TANK VENT TUBE SET PLATE

FUEL SUCTION TUBE ASSEMBLY

WITH PUMP AND GAUGE

GASKET

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
A136244E01
 2AZ-FE FUEL – FUEL TANK FU–33

NO. 1 FUEL TUBE

FUEL TANK ASSEMBLY

FUEL TANK TO
For SE Grade: FILLER PIPE HOSE

FUEL TANK PROTECTOR LOWER CENTER

FUEL TANK PROTECTOR
LOWER CENTER x4

5.4 (55, 48 in.*lbf)

FU

39 (400, 29)
PIN
FUEL TANK BAND
NO. 2 PARKING BRAKE 39 (400, 29)
CABLE ASSEMBLY
FUEL TANK BAND

6.0 (61, 53 in.*lbf) PIN

8.5 (87, 75 in.*lbf)

GASKET

6.0 (61, 53 in.*lbf)

NO. 3 PARKING BRAKE
CABLE ASSEMBLY
8.5 (87, 75 in.*lbf)

GASKET
43 (438, 32)

CENTER EXHAUST PIPE ASSEMBLY

56 (571, 41)

Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque

A136747E01
 FU–34 2AZ-FE FUEL – FUEL TANK

FUEL PUMP TUBE SUB-ASSEMBLY

FUEL TANK ASSEMBLY

NO. 2 FUEL TANK X7

CUSHION FUEL TANK VENT HOSE

FU

CLIP NUT X4 5.4 (55, 48 in.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque

FUEL MAIN TUBE SUPPORT
Non-reusable part

A109012E08
 2AZ-FE FUEL – FUEL TANK FU–35

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY (for
Fixed Seat Type) (See page SE-77)
4. REMOVE REAR SEAT CUSHION ASSEMBLY (for
Fold Down Seat Type) (See page SE-47)
5. REMOVE REAR SEAT CUSHION ASSEMBLY (for
Reclining Seat Type) (See page SE-62)
6. REMOVE REAR FLOOR SERVICE HOLE COVER (See
page FU-27)
7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See
page FU-27)
8. REMOVE FUEL TANK VENT TUBE SET PLATE (See
page FU-28)
FU
9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH
PUMP AND GAUGE (See page FU-28)
10. DRAIN FUEL
11. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See
page EX-2)
12. DISCONNECT NO. 2 PARKING BRAKE CABLE
ASSEMBLY
(a) Remove the set bolt and set nut of the No. 2 parking
brake cable assembly.

A135222

13. DISCONNECT NO. 3 PARKING BRAKE CABLE

ASSEMBLY
(a) Remove the set bolt and set nut of the No. 3 parking
brake cable assembly.

A135223
 FU–36 2AZ-FE FUEL – FUEL TANK

14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET

(a) Remove the 4 bolts and 2 rear stabilizer bar No. 1
brackets.

A136008E01

15. REMOVE FUEL TANK PROTECTOR LOWER CENTER

(a) Remove the 4 bolts and fuel tank protector (Except
SE Grade).

FU A135224

(b) Remove the 4 bolts and 2 clips (for SE Grade).

(c) Remove the fuel tank protector (for SE Grade).

Clip

A135225E01

16. REMOVE FUEL TANK ASSEMBLY

(a) Disconnect the fuel pump tube.
Pinch (1) Pinch the tab of the retainer to disengage the
lock claws and pull it down as shown in the
illustration.
(2) Pull out the fuel tank main tube.
NOTICE:
Pull Retainer • Check that there is no dirt or other
foreign objects around the connector
Pull
Pinch before this operation and clean the
connector as necessary.
• It is necessary to prevent mud or dirt
Fuel Tube Connector Retainer from entering the quick connector. If mud
enters the connector, the O-rings may
not seal properly.
• Remove the quick connector by hand.
• Do not bend or twist the nylon tube.
Protect the connector by covering it with
Pipe a plastic bag.
O-Ring
A121573E02
 2AZ-FE FUEL – FUEL TANK FU–37

• If the pipe and connector are stuck, try

wiggling or pushing and pulling the
connector to release it and pull the
connector off of the pipe carefully.
(b) Disconnect the No. 1 fuel tube.
(1) Pinch the tube connector and then pull out the
Pinch No. 1 fuel tube.
NOTICE:
Pull • Check that there is no dirt or other
foreign objects around the connector
Pinch before this operation and clean the
connector if necessary.
• It is necessary to prevent mud or dirt
from entering the quick connector. If mud
enters the connector, the O-rings may
not seal properly.
Tube Connector • Remove the quick connector by hand.
Nylon Tube
• Do not bend or twist the nylon tube.
Protect the connector by covering it with
a plastic bag.
• If the pipe and connector are stuck, try FU
wiggling or pushing and pulling the
Pipe connector to release it and pull the
O-Ring connector off of the pipe carefully.
A121576E01

(c) Place a engine lifter under the fuel tank assembly.

A136009
 FU–38 2AZ-FE FUEL – FUEL TANK

(d) Remove the 2 set bolts of the fuel tank bands. (*1)
(e) Remove the hose clamp and disconnect the fuel
tank to filter pipe hose. (*2)
(f) Slightly lower the transmission jack.
(g) Disconnect the fuel tank vent hose from the
charcoal canister. (*3)
(1) Push the connector deep into the charcoal
canister to release the locking pin.
(*1) (*1) (2) Pinch portion A.
Pinch (3) Pull out the connector.
(h) Remove the fuel tank.
(*3)
Push

Pinch A

(*2)
A

FU A091352E05

(i) Remove the 2 pins and 2 fuel tank bands as shown

in the illustration.

A079478

(j) Remove the 4 clip nuts (Except SE Grade).

A136004

(k) Remove the 4 clip nuts (for SE Grade).

A136005
 2AZ-FE FUEL – FUEL TANK FU–39

17. REMOVE FUEL TANK VENT HOSE

(a) Push the connector deep into the charcoal canister
to release the locking pin.
Push A A (b) Pinch portion A.
(c) Pull out the connector.
Pinch

Pinch
A079479E03

18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY

(a) Remove the fuel pump tube from the fuel main tube
support.

A079480
FU
19. REMOVE FUEL MAIN TUBE SUPPORT
(a) Remove the bolt and tube support.

A079481

20. REMOVE NO. 2 FUEL TANK CUSHION

(a) Remove the 7 No. 2 fuel tank cushions.

A079484

INSTALLATION
1. INSTALL NO. 2 FUEL TANK CUSHION
(a) Install 7 new No. 2 fuel tank cushions to the fuel
tank.

A079484
 FU–40 2AZ-FE FUEL – FUEL TANK

2. INSTALL FUEL MAIN TUBE SUPPORT

(a) Install the fuel main tube support with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

A079481

3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY

(a) Install the fuel pump tube to the fuel main tube
support.

FU A079480

4. INSTALL FUEL TANK VENT HOSE

(a) Install the fuel tank vent hose.

A129490

5. INSTALL FUEL TANK ASSEMBLY

(a) Install the 4 clip nuts (Except SE Grade).

A136004

(b) Install the 4 clip nuts (for SE Grade).

A136005
 2AZ-FE FUEL – FUEL TANK FU–41

(c) Install the 2 fuel tank bands with the 2 pins.

(d) Set the fuel tank assembly onto the transmission
jack.

A129491

(e) Raise the transmission jack so that the fuel tank

vent hose can be connected. (*1)
NOTICE:
Slowly raise the jack to prevent the fuel tank
assembly from dropping.
(f) Connect the fuel tank inlet pipe with the fuel filter
pipe clamp. (*2)
(g) Tighten the 2 set bolts of the fuel tank bands. (*3)
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

(*3)
FU
(*1) (*3)

(*2)

A129492E02

(h) Connect the No. 1 fuel tube.

Fuel Tube Connector
(1) Push the fuel tube connector into the pipe until
the fuel tube connector makes a "click" sound.
NOTICE:
• Before connecting the tube, make sure
that it is not damaged. Make sure that
there is no dirt present on the connecting
Pipe surfaces.
• After connecting, check if the fuel tube
A091572E03 connector and the pipe are securely
connected by pulling on them.
(i) Connect the fuel pump tube.
(1) Push the fuel connector into the pipe and push
up the retainer so that the claws engage.
NOTICE:
• Before connecting the tube, make sure
that it is not damaged. Make sure that
Retainer there is no dirt present on the connecting
surfaces.

A081598E03
 FU–42 2AZ-FE FUEL – FUEL TANK

• After connecting, check if the fuel tube

connector and the pipe are securely
connected by pulling on them.
6. INSTALL FUEL TANK PROTECTOR LOWER CENTER
(a) Install the 4 bolts and fuel tank protector (Except SE
Grade).
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

A135224

(b) Install the fuel tank protector with the 4 bolts and 2
clips (for SE Grade).
Torque: Bolt
5.4 N*m (55 kgf*cm, 48 in.*lbf)
Clip
FU

A135225E01

7. INSTALL REAR STABILIZER BAR NO. 1 BRACKET

(a) Install the 2 rear stabilizer bar No. 1 brackets with
the 4 bolts.
Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf)

A136008E01

8. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY

(a) Install the No. 3 parking brake cable assembly with
the bolt and nut.
Torque: Bolt
6.0 N*m (61 kgf*cm, 53 in.*lbf)
Nut
8.5 N*m (87 kgf*cm, 75 in.*lbf)

A135223
 2AZ-FE FUEL – FUEL TANK FU–43

9. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY

(a) Install the No. 2 parking brake cable assembly with
the bolt and nut.
Torque: Bolt
6.0 N*m (61 kgf*cm, 53 in.*lbf)
Nut
8.5 N*m (87 kgf*cm, 75 in.*lbf)
10. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See
page EX-4)
A135222

11. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH

PUMP AND GAUGE (See page FU-32)
12. INSTALL FUEL TANK VENT TUBE SET PLATE (See
page FU-32)
13. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (See
page FU-33)
14. ADD FUEL
15. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL FU
16. CHECK FOR FUEL LEAKS (See page FU-8)
17. CHECK FOR EXHAUST GAS LEAKS
18. INSTALL REAR FLOOR SERVICE HOLE COVER
19. INSTALL REAR SEAT CUSHION ASSEMBLY (for
Fixed Seat Type) (See page SE-84)
20. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold
Down Seat Type) (See page SE-58)
21. INSTALL REAR SEAT CUSHION ASSEMBLY (for
Reclining Seat Type) (See page SE-73)