Engine Fuel System (1GR-FE): Overview Toyota 4Runner IV рестайлинг

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1. PRECAUTION Before starting on the work for the 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 FOR 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. HINT: 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 (See «REMOVAL»(ref-280571-S05740694472008022200000) ). Drain the fuel remained inside the fuel pump tube. In order to prevent the disconnected fuel pump tube from damaging and foreign objects from 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 a new O-ring on the injector, do not damage it. Coat the new O-rings with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake oil. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. 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. 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 from 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 no 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 a 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 from 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 the axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connection is tight, apply a 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 FOR FUEL LEAK Check that there are no fuel leaks after doing maintenance to the fuel system (See «ON-VEHICLE INSPECTION»(ref-280571-S13399001902008022200000) ).

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1. CHECK FUEL PUMP OPERATION AND FUEL LEAK When using the intelligent tester Connect the intelligent tester to the DLC3. Turn the ignition switch ON and intelligent tester main switch ON. NOTE: Do not start the engine. Select the ACTIVE TEST mode on the intelligent tester. Please refer to the intelligent tester operator's manual for further details. When not using the intelligent tester Remove the circuit opening relay. Using a service wire, connect terminals FP and +B of the relay block. NOTE: Pay due attention to the terminal connecting position to avoid a malfunction. 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 intelligent tester from the DLC3.
2. CHECK FUEL PRESSURE Prepare for inspection. Prepare a new fuel tube, and take out the fuel tube connector from the tube. HINT: Part No. 23801-31070 Prevent gasoline from spilling out (See «FUEL SYSTEM»(ref-280571-S12443290642008022200000) ). Disconnect the EFI fuel pipe clamp (See «FUEL SYSTEM»(ref-280571-S12443290642008022200000) ). Disconnect the fuel pipe No. 1 from the fuel main tube. Install SST (pressure gauge) as shown in the illustration by using the SSTs and a fuel tube connector. SST 09268-31011 (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 the fuel main tube. Install the EFI fuel pipe clamp. Check for fuel leak.

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «FUEL SYSTEM»(ref-280571-S12443290642008022200000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
4. REMOVE V-BANK COVER (See «REMOVAL»(/toyota/4runner/iv-2005-2009/remont/testing-diagnostics/#engine-control-system-1gr-fe) )
5. DISCONNECT NO. 2 VENTILATION HOSE Disconnect the No. 2 ventilation hose.
6. REMOVE AIR CLEANER ASSEMBLY (See «REMOVAL»(/toyota/4runner/iv-2005-2009/remont/testing-diagnostics/#engine-control-system-1gr-fe) )
7. REMOVE INTAKE AIR SURGE TANK Disconnect the No. 5 water by-pass hose. Disconnect the No. 4 water by-pass hose. Disconnect the fuel vapor feed hose. Disconnect the ventilation hose. Disconnect the 2 VSV connectors. Disconnect the throttle motor connector. Remove the 3 wire harness clamps and hose clamp. Remove the 3 upper bolts which are used to secure the 2 surge tank stays and throttle body bracket. Using an 8 mm socket hexagon wrench, remove the 4 bolts. Remove the 2 nuts, then remove the intake air surge tank and gasket.
8. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Remove the fuel pipe clamp. Pinch the tube connector, and then pull the fuel pipe out of the pipe as shown in the illustration. NOTE: Remove any dirt and foreign objects from the fuel tube connector before performing this work. Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the nylon tube. Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube. If the fuel tube connector and pipe are stuck, push and pull to release them.
9. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Remove the fuel pipe clamp. Pinch the tube connector, and then pull the fuel pipe out of the pipe as shown in the illustration. NOTE: Remove any dirt and foreign objects from the fuel tube connector before performing this work. Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the nylon tube. Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube. If the fuel tube connector and pipe are stuck, push and pull to release them.
10. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Disconnect the 6 fuel injector connectors. Remove the 6 bolts and fuel delivery pipe together with the 6 fuel injectors. NOTE: Be careful not to drop the injectors when removing the fuel delivery pipe.
11. REMOVE FUEL INJECTOR Pull the 6 injectors out of the delivery pipe.

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1. INSPECT FUEL INJECTOR ASSEMBLY Check the resistance. Using an ohmmeter, measure the resistance between the terminals. Standard FUEL INJECTOR ASSEMBLY Tester Connection Specified Condition 1-2 11.6 to 12.4ohms at 20°C (68°F) If the result is not as specified, replace the fuel injector. Check the injection volume. NOTE: Perform the test in a well-ventilated area and watch out for flames. Handle the fuel tube connector carefully. Prepare a new fuel tube. HINT: Part No. 23801-31070 Using a cutter knife, cut the fuel tube protector. Tear the protector by hand, then remove the fuel tube connector. NOTE: If the protector is cut too deeply with the cutter, the O-ring of the fuel tube connector will be damaged. Install the fuel tube connector into SST (hose), then connect the tube connector to the fuel pipe. SST 09268-41047 (95336-08070) CAUTION: Connect the fuel tube connector (quick type) after observing the precautions. Remove the pressure regulator (See «REMOVAL»(ref-280571-S20466850062008022200000) ). Install the O-ring onto the fuel inlet of the pressure regulator. Connect 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 a new O-ring onto the injector. Connect SST (adaptor and hose) to the injector and hold the injector and union with SST (clamp). SST 09268-41047 (95336-08070), 09268-41140, 09268-41400 Set the injector in a graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to prevent gasoline splashes. Connect the intelligent tester to the DLC3. Turn the ignition switch to ON. Turn the intelligent tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD / ON. Install SST onto the fuel injector. SST 09842-30080 Connect SST to the battery, then measure the injection volume for 15 seconds. Perform the inspection 2 or 3 times, then calculate the average. Standard: INJECTION VOLUME SPECIFICATION Injection Volume Difference Between Each Fuel Injector 76 to 91 cm 3 (4.6 to 5.5 cu in.) per 15 seconds 15 cm 3 (0.9 cu in.) or less NOTE: Always do the switching at the battery side. If the result is not as specified, replace the fuel injector. Check the fuel leakage. When checking the injection volume, remove SST from the battery. Inspect the fuel leakage from the fuel injector. SST 09842-30080 Standard: 1 drop or less every 12 minutes. If the result is not as specified, replace the fuel injector.

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1. INSTALL FUEL INJECTOR Install a new insulator onto each fuel injector. Apply a light coat of spindle oil or gasoline to a new O-ring and install it onto each fuel injector. While turning the fuel injector left and right, install it onto the fuel delivery pipe. Position the fuel injector connector facing outward.
2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Place the fuel delivery pipe together with the 6 fuel injectors on the intake manifold. Provisionally install the 6 bolts, which are used to hold the fuel delivery pipe, onto the intake manifold. Check that the fuel injectors rotate smoothly. HINT: If the fuel injectors do not rotate smoothly, replace the O-ring. Position the fuel injector connector facing outward. Tighten the 6 bolts, which are used to hold the fuel delivery pipe, to the intake manifold. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) Connect the 6 fuel injector connectors.
3. CONNECT FUEL PIPE SUB-ASSEMBLY Push the tube connector into the pipe until the tube connector makes a "click" sound. NOTE: Check if there is any damage or foreign objects on the connected part of the fuel pipe. After connecting, check that the pipe and connector are securely connected by pulling them. Install the fuel pipe clamp.
4. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Push the tube connector into the pipe until the tube connector makes a "click" sound. NOTE: Check if there is any damage or foreign objects on the connected part of the fuel pipe. After connecting, check that the pipe and connector are securely connected by pulling them. Install the fuel pipe clamp.
5. INSTALL INTAKE AIR SURGE TANK Install a new gasket and the intake air surge tank with the 2 nuts. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) Using an 8 mm socket hexagon wrench, install the 4 bolts. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) Install the 3 upper bolts which are used to secure the 2 surge tank stays and throttle body bracket. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) Install the 3 wire harness clamps and hose clamp. Connect the throttle motor connector. Connect the 2 VSV connectors. Connect the ventilation hose. Connect the fuel vapor feed hose. Connect the No. 4 water by-pass hose. Connect the No. 5 water by-pass hose.
6. INSTALL AIR CLEANER ASSEMBLY (See «INSTALLATION»(/toyota/4runner/iv-2005-2009/remont/testing-diagnostics/#engine-control-system-1gr-fe) )
7. CONNECT NO. 2 VENTILATION HOSE Connect the No. 2 ventilation hose.
8. INSTALL V-BANK COVER (See «INSTALLATION»(/toyota/4runner/iv-2005-2009/remont/testing-diagnostics/#engine-control-system-1gr-fe) )
9. CONNECT BATTERY NEGATIVE TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
10. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
11. CHECK FOR ENGINE COOLANT LEAKAGE (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
12. CHECK FOR FUEL LEAK

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «FUEL SYSTEM»(ref-280571-S12443290642008022200000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE V-BANK COVER (See «REMOVAL»(/toyota/4runner/iv-2005-2009/remont/testing-diagnostics/#engine-control-system-1gr-fe) )
4. DISCONNECT NO. 2 VENTILATION HOSE Disconnect the No. 2 ventilation hose.
5. REMOVE AIR CLEANER ASSEMBLY (See «REMOVAL»(/toyota/4runner/iv-2005-2009/remont/testing-diagnostics/#engine-control-system-1gr-fe) )
6. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY (See «REMOVAL»(ref-280571-S35920585772008022200000) )
7. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY Remove the 2 bolts, then remove the fuel pressure regulator. Remove the vacuum hose.

See also:
• REMOVAL