Engine Fuel System - 1GR-FE Toyota 4Runner IV

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1. PRECAUTION Before working on fuel system inspection and repair, disconnect the negative (-) terminal cable from the battery. Do not smoke or work near fire when handling the fuel system. Keep gasoline away from rubber or leather parts.
2. WORK TO PREVENT GASOLINE FROM SPILLING OUT CAUTION: Take precaution for preventing gasoline from spilling out before removing the fuel system parts. As there is the remained pressure in the fuel line after working for prevent gasoline from spilling out, prevent it from splashing inside the vehicle compartment by covering them with a shop rag. Remove the circuit opening relay from the engine room relay block. Start the engine. After the engine stopped, turn the ignition switch OFF. NOTE: There is a case that DTC P0171 (system to lean) is output. Check that the engine does not start. Remove the fuel tank cap, and let the air out of the fuel tank. Disconnect the negative (-) terminal cable from the battery. Reinstall the circuit opening relay.
3. FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. Disconnect the fuel pump tube. Drain the fuel remaining inside the fuel pump tube. Prevent the disconnected fuel pump tube from damaging and foreign objects being mixed into cover them with a vinyl bag. Put a container under the connection. Observe these precautions when removing and installing the injectors. Never reuse the O-ring. When placing the new O-ring on the injector, do not damage the O-ring. Coat the new O-rings with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake oil. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or cylinder head contacts the O-ring of the injector. Install the injector to the delivery pipe and lower intake manifold (Scheme 4) Observe these precautions when disconnecting the fuel tube connector (Quick type A): Remove the fuel pipe clamp No. 1. Check that there is no dirt like mud on the pipe and around the connector before disconnecting them. Clean them if necessary. Disconnect them by hand. When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Inspect that there is no dirt or the like on the seal surface of the disconnected pipe. Clean it away if necessary. In order to prevent the disconnected pipe and connector from damaging and foreign objects being mixed into, cover them with a vinyl bag. Observe these precautions when connecting the fuel tube connector (Quick Type A): Check that there is on damage or foreign objects in the connected part of the pipe. Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply little amount of fresh engine oil on the tip of the pipe. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. Check for any fuel leak. Observe these precautions when disconnecting the fuel tube connector (Quick type B): Check if there is any dirt like mud on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. Disconnect them by your hands. When the connector and the pipe are stuck, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe. Clean it away if necessary. Prevent the disconnected pipe and connector from damaging and foreign objects being mixed into by covering them with a vinyl bag. Observe these precautions when connecting the fuel tube connector (Quick type B): Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. Check for fuel leakage. Observe these precautions when handling nylon tube. CAUTION: Be careful not to turn the connection part of the nylon tube and the quick connector when connecting them. Do not kink the nylon tube. Do not remove the EPDM protector on the outside of the nylon tube. Do not close the piping with the nylon tube by bending it.
4. CHECK FUEL LEAK Check that there are no fuel leaks after doing maintenance to the fuel system. (See «ON-VEHICLE INSPECTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) )

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1. CHECK FUEL PUMP OPERATION AND FUEL LEAK When using the hand-held tester Connect the hand-held tester to the DLC3. NOTE: Do not start the engine. Turn the ignition switch ON and hand-held tester main switch ON. Select the ACTIVE TEST mode on the hand-held tester. Please refer to the hand-held tester operator's manual for further details. When not using hand-held tester Remove the circuit opening relay. CAUTION: Pay due attention to the terminal connecting position to avoid a malfunction. Using a service wire, connect terminals FP and +B of the relay block. Turn the ignition switch ON, and check that the fuel pump operates. NOTE: Do not start the engine. Check that there are no fuel leaks after doing maintenance to the fuel system. Turn the ignition switch OFF. Disconnect the hand-held tester from the DLC3.
2. CHECK FUEL PRESSURE Prepare for inspection. NOTE: Part No. 23801-31070 Prepare a new fuel tube, and take out the fuel tube connector from the tube. Prevent gasoline from spilling out (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) ). Disconnect the EFI fuel pipe clamp (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) ). Disconnect the fuel pipe No. 1 from the fuel main tube. Install SST (pressure gauge) (Scheme 14)by using the SSTs and a fuel tube connector. SST 09268-41047 (90467-13001, 95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250, 90467-13001) Wipe off any splattered gasoline. Start the engine. Measure the fuel pressure at idle Fuel pressure: 281 - 287 kPa (2.87 - 2.93 kgf.cm 2, 40.8 - 41.7 psi) Stop the engine. Check that the fuel pressure remains as specified for 5 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. After checking the fuel pressure, disconnect the negative (-) terminal cable from the battery carefully, remove the SST and fuel tube connector to prevent gasoline from the splashing. Reconnect the fuel tube to fuel main tube. Install the EFI fuel pipe clamp. Check for fuel leak (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) ).

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1. INSPECT FUEL INJECTOR ASSY Inspect injector resistance Using an ohmmeter, measure the resistance between the terminals. Resistance: 11.6 - 12.4 ohm at 20°C (68°F) If the resistance is not as specified, replace the injector. CAUTION: Keep injector clear of sparks during the test. Inspect injector inspection Obtain the new No.1 fuel pipe (part No. 23801 - 31070) and take out the fuel tube connector from the pipe. CAUTION: Connect the fuel tube connector (quick type) after observing the precautions. Install the fuel tube connector to a SST (hose), then connect the tube connect and fuel pipe. SST 09268-41047 (95336-08070) Remove the pressure regulator from the delivery pipe. Install the O-ring to the fuel inlet of the pressure regulator. Connect the SST (hose) to the fuel inlet of the pressure regulator with another SST (union) and the 2 bolts. SST 09268-41047 (95336-08070, 09268-41091) Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf) Connect the fuel return hose to the fuel outlet of the pressure regulator. Install the O-ring to the injector. Connect SSTs (adaptor and hose) to the injector, and hold the injector and union with SST (clamp) SST 09268-41047 (09268-41140, 09268-41400, 95336-08070) CAUTION: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out. Put the injector into a graduated cylinder. Operate the fuel pump. (See «ON-VEHICLE INSPECTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) ) Connect an SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842 - 30080 Volume: 76 - 91 cm 3 (4.6 - 5.5 cu in.) per 15 seconds difference between each injector: 15 cm 3 (0.9 cu in.) or less If the injection volume is not as specified, replace the injector. Inspect leakage In the condition above, disconnect the tester probes of the SST (wire) from the battery and check the fuel leakage from the injector. SST 09842 - 30080
2. INSPECT FUEL PUMP RESISTER Inspect the fuel pump resistor resistance. Using an ohmmeter, measure the resistance between terminal. Fuel drop: 1 drop or less per 12 minutes Resistance: 0.70 - 0.76 ohm at 20°C (68°F)
3. INSPECT FUEL PUMP Inspect fuel pump resistance. Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 ohm at 20°C (68°F) Inspect fuel pump operation Apply the battery voltage to both terminals. Check that the pump operates.
4. INSPECT FUEL PUMP RELAY ASSY Continuity inspection. Using the ohmmeter, check that there is continuity between each terminal. FUEL PUMP RELAY TERMINALS SPECIFIED CONDITION Between Terminals Specified Condition 1 - 2 Continuity 3 - 4 Continuity 3 - 5 No continuity Using the ohmmeter, check that there is continuity between terminals 3 and 5 when the battery voltage is applied across terminals 1 and 2. Specified condition: Continuity

See also:
• ON-VEHICLE INSPECTION