Changing The Fuel Filter In Your Mr2: Step-By-Step Guide

Changing the fuel filter on a Toyota MR2 is a maintenance task that can be completed in a few hours. While it's not a routine service item, it may be beneficial to change the fuel filter if your car is over 15 years old, as it could improve gas mileage. Before starting, ensure you have the necessary tools and safety equipment, including eye protection, latex gloves, and a fire extinguisher, as you will be working with flammable fuel. The process involves relieving the pressure on the fuel lines, removing the old fuel filter, and installing a new one, ensuring all bolts are tightened correctly and there are no leaks.

Relieve pressure on fuel lines

To relieve the pressure on the fuel lines of your MR2, follow these steps:

Firstly, make sure the key is out of the ignition. Disconnect the negative terminal from the battery to prevent any sparks from igniting the fuel. You can also open the fuel filler cap to release pressure from the tank and stop fuel from constantly coming out of the main fuel line.

Now, relieve the pressure on the fuel lines by removing the EFI 15A fuse. Check that this is the correct fuse for your model. This will disable the fuel pump.

Next, crank the car as you would normally when starting it. The car should not start, as there is no fuel pressure to feed the injectors. Try starting the car about seven times.

Jack up the rear of the car and support it on jack stands. Crawl under the car, under where the battery sits on the driver's side. You will see the firewall. Cover the ratchet and bolt with a rag or two as you loosen the banjo bolt with a 17mm socket. You may want to place a pan under the filter to catch any dripping fuel. Wear goggles, as fuel in the eyes can be extremely painful. When you loosen the bolt, you will get some sprayage of gas. If it continues spraying, tighten the bolt back up and crank the car a few more times to relieve the pressure. When fuel stops coming out of the hose and filter, remove the banjo bolt completely.

Disconnect negative battery terminal

Disconnecting the negative battery terminal is a standard safety procedure when working on your car. It is important to prevent any sparks from igniting fuel and causing injury or fire.

• Make sure the car engine is turned off. Never attempt to remove a battery while the engine is on as it can spike sensitive electronics and cause damage.
• Locate the battery. On the MR2, it is found under the hood, in the engine bay, between the driver's seat and the driver-side rear wheel.
• Identify the battery terminals. The negative terminal is usually denoted by a "-" symbol and a black cable, while the positive terminal has a "+" symbol and a red cable.
• Using a wrench, loosen the nut on the negative terminal first. Ensure that you do not touch any metal part of the wrench to the positive terminal or any other metal component of the car to avoid creating a short circuit.
• Remove the nut and take the cable off the battery post. Ensure that the cable is kept away from the battery terminals.

By following these steps, you will have successfully disconnected the negative battery terminal on your MR2, making it safe to proceed with changing the fuel filter. Remember to always put safety first when working on your vehicle.

Locate and remove the fuel filter

To locate and remove the fuel filter of a Toyota MR2, you will need the following tools:

• A medium-sized ratchet
• A 17mm socket
• An 11mm socket
• An extension
• Needle-nose vise-grips
• PB Blaster
• An oil drain pan
• Shop rags
• Latex gloves
• Eye protection
• A floor jack
• A jack stand
• Wheel stops
• A Phillips screwdriver
• A 1/2 drive breaker bar
• A 1/2 -> 3/8 drive adapter
• A 3/8 socket drive
• A 1/4 socket drive
• A 10-inch 3/8 drive extension
• A 6-inch 3/8 drive extension
• A 3-inch 3/8 drive extension
• Two large bath towels
• A small hand towel
• A large 5000-10000 CFM fan
• A safety drop light
• A torque wrench that goes to at least 22 ft lbs

Before you begin, ensure that the key is out of the ignition and consider disconnecting the negative terminal from the battery to prevent any sparks from igniting fuel. The fuel filter is located in the engine bay between the driver's seat and the driver-side rear wheel. To access it from the top, remove the air intake system. Remove the driver-side engine lid panel for better access.

Locate the fuel filter and coat all the bolts with PB Blaster. First, you will want to drain the filter by slowly loosening the bolt to the fuel pressure line at the bottom of the filter with the 17mm socket. Fuel will start dripping or streaming, so have the drain pan readily available, along with the vice-grips and a shop rag. It is recommended to wear eye protection in case of fuel spray or drip splashes.

Wait a few seconds for some fuel to drain, and then apply the vice-grips to the rubber portion of the fuel pressure line. You can use a rag to cover the teeth of the vice-grips to protect the fuel line. Use a minimum amount of pressure to slow the fuel leak, then completely remove the bolt and disconnect the line. Reapply the vice-grips with a bite just tight enough to stop the drip.

Remove the other line from above, also using the 17mm socket. With the 11mm socket, loosen the bolt on the mounting bracket that is clamping onto the fuel filter. From under the car, remove the other two bolts of the bracket. The fuel filter can now be removed. Study the position of the fuel filter in the bracket and determine how the new filter will need to sit.

Install new fuel filter

To install a new fuel filter in your MR2, you will need the following tools: a medium-sized ratchet, a 17mm socket, an 11mm socket, an extension, needle-nose vise-grips, PB Blaster, an oil drain pan, shop rags, latex gloves, eye protection, a floor jack, a jack stand, wheel stops, and a Phillips screwdriver. It is also recommended to wear protective clothing and have adequate ventilation or perform the task outdoors.

Begin by relieving the pressure on the fuel lines. Do this by removing the EFI 15A fuse and cranking the car as you normally would when starting it. The car should not start as there is no fuel pressure to feed the injectors. Try cranking the car a few times to ensure the fuel pressure is relieved.

Jack up the rear of the car and secure it on jack stands. Locate the fuel filter in the engine bay, typically between the driver's seat and the driver's side rear wheel. You may need to remove the air intake system and the driver's side engine lid panel for better access.

Before removing the fuel filter, coat all the bolts with PB Blaster. Drain the filter by slowly loosening the bolt to the fuel pressure line at the bottom of the filter using the 17mm socket. Fuel will start dripping or streaming, so have the drain pan ready and wear eye protection. Once fuel starts dripping, apply vice-grips on the rubber portion of the fuel pressure line. Cover the teeth of the vice-grips with a rag to protect the fuel line. Use minimal pressure to slow the fuel leak, then completely remove the bolt and disconnect the line.

Remove the other line from the top using the 17mm socket. With the 11mm socket, loosen the bolt on the mounting bracket clamping the fuel filter. From under the car, remove the other two bolts of the bracket. The fuel filter is now free. Study the position of the old fuel filter in the bracket to understand how the new filter will need to be oriented.

Install the new fuel filter by first attaching the mounting bracket to the new filter in the same way as the old one. Reinstall the mounting bracket and reconnect the top fuel line, using new copper washers on each side of the hose. Reconnect the fuel line on the bottom using the last two copper washers. Ensure all bolts are tight, then remove the vice-grips and lower the car to the ground, checking that nothing is left underneath.

Reinstall the intake and give a final inspection before attempting to start the car. The car may need a few attempts to start. Once the engine starts, check for any leaking fuel. If there are no leaks, go for a test drive.

Check for leaks

After you've replaced the fuel filter in your MR2, it's important to check for leaks to ensure the safety and proper functioning of your vehicle. Here's a detailed guide on how to do it:

Step 1: Turn the Ignition On

Turn the ignition to the "ON" position without cranking the car. This will activate the fuel pump and build pressure in the fuel lines. Let it sit for around 10 to 15 seconds.

Step 2: Start the Engine

Try starting the engine. It may take a few attempts, so be patient and give it a few seconds between each attempt. Once the engine starts, let it idle.

Step 3: Inspect for Leaks

With the engine idling, carefully inspect the area around the fuel filter and the banjo bolts for any signs of fuel leaks. Pay close attention to the banjo bolts, as they are a common source of leaks. If you notice any fuel dripping or spraying, address the leak immediately.

Step 4: Test Drive

If you don't notice any leaks, turn off the engine and remove the car from the jack stands, if you have it propped up. Then, take the car for a short test drive. Keep an eye—and ear—out for any unusual behaviour, such as strange noises or warning lights. If everything seems fine, congratulate yourself on a job well done!

Tips for Leak Prevention:

• Always use new copper washers when reconnecting fuel lines to ensure a tight seal.
• Torque the banjo bolts to the recommended 22 ft-lb.
• Before tightening bolts, ensure that old washers are removed and replaced with new ones.
• When working with fuel, always wear eye protection and protective clothing to shield yourself from sprays or drips.

Frequently asked questions