Engine Fuel System (2UZ-FE): Overview Toyota 4Runner IV рестайлинг

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1. PRECAUTION Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. Do not smoke or work near fire when working on the fuel system. Keep gasoline away from rubber or leather parts.
2. WORK FOR PREVENT GASOLINE FROM SPILLING OUT CAUTION: Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. Even after discharging the fuel pressure, place a shop rag or piece of cloth over fittings to prevent fuel splashing on yourself or in the engine compartment when separating the fittings. Remove the circuit opening relay from the engine room relay block. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT: There is a case that DTC P0171 (system too 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. (Scheme 1): Identifying C/OPN Relay
3. FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: Disconnect the fuel pump tube (See «REMOVAL»(ref-280563-S28867147592008022200000) ). Drain the fuel remained inside the fuel pump tube. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. (Scheme 2): Covering Pipe And Connector With Plastic Bag Place a container under the connection. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe the following procedures: Always use new gaskets. Tighten the union bolt by hand. (Scheme 3): Identifying Union Bolt And Gaskets Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: for use with SST 33 N*m (340 kgf*cm, 24 ft.*lbf) 39 N*m (400 kgf*cm, 29 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in). (Scheme 4): Tightening Union Bolt Observe the following precautions when removing and installing the injectors: Never reuse the O-ring. When placing a new O-ring on the injector, do not damage the O-ring. Coat the new O-ring with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake fluid. (Scheme 5): Identifying Correct And Incorrect Position Of O-Ring Install the injector to the delivery pipe and lower intake manifold, as shown in the illustration. NOTE: Before installing the injector, apply spindle oil or gasoline where the delivery pipe or intake manifold contacts the O-ring of the injector. (Scheme 6): Installing Injector To Delivery Pipe And Lower Intake Manifold Observe the following precautions when disconnecting the fuel tube connector (Quick type A): Remove the fuel pipe clamp No. 1. (Scheme 7): Identifying Fuel Pipe Clamp No. 1 Check that there is no dirt 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 your fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out of the pipe. (Scheme 8): Pulling Connector Out From Pipe Check that there is no dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. Observe the following 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 small amount of fresh engine oil to the tip of the pipe. (Scheme 9): Pushing Connector After finishing the connection, check if the pipe and the connector are securely connected by pulling them. Check for fuel leaks. (Scheme 10): Pulling Connector Observe the following precautions when disconnecting the fuel tube connector (Quick type B): Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. Disconnect them by hand. When the connector and the pipe are stuck, push and pull the connector. Disconnect and pull it out. Do not use any tool at this time. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. (Scheme 11): Pulling And Pushing Connector Observe the following 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 small amount of new engine oil to the tip of the pipe. (Scheme 12): Pushing Connector After finishing the connection, check if the pipe and the connector are securely connected by pulling them. Check for fuel leaks. (Scheme 13): Pulling Connector Observe the following precautions when disconnecting the fuel tube connector (Quick type C): Pull the fuel hose connector cover up to release the lock. Check that there is no dirt in the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. Be sure to disconnect them by hand. (Scheme 14): Pulling Fuel Hose Connector Cover When the connector and the pipe are stuck, pinch the fuel pipe between the hands, and push and pull the connector. Disconnect and pull it out. Do not use any tool at this time. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. (Scheme 15): Pushing And Pull Connector Observe the following precautions when connecting the fuel tube connector (Quick Type C): 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 small amount of fresh engine oil to the tip of the pipe. (Scheme 16): Pushing Fuel Tube Connector After finishing the connection, check if the pipe and the connector are securely connected by pulling them. (Scheme 17): Pulling Fuel Tube Connector Lock the fuel hose connector cover. HINT: If the fuel tube is not completely connected, the half connection prevention connector prevents the fuel hose connector cover from being locked. Check for fuel leaks. Observe the following precautions when handling a nylon tube: CAUTION: Do not twist the connection part of the nylon tube and the quick connector by force when connecting them. Do not twist 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. (Scheme 18): Locking Fuel Hose Connector Cover
4. CHECK FOR FUEL LEAK Check that there are no fuel leaks anywhere on the fuel system after doing maintenance (See «FUEL SYSTEM»(ref-280563-S42721263222008022200000) ).

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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. (Scheme 19): Connecting Terminals FP And +B Of 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 anywhere on the fuel system. Check that the pulsation damper screw rises up when the fuel pump operates. If operation is not as specified, check the following parts: Fusible link Fuses EFI main relay Fuel pump ECM Wiring connections Turn the ignition switch OFF. Disconnect the intelligent tester from the DLC3. (Scheme 20): Identifying Pulsation Damper Screw
2. CHECK FUEL PRESSURE Check the battery positive voltage is above 12 V. Disconnect the negative (-) terminal cable from the battery. Remove the front fuel pipe from the LH delivery pipe (See «REMOVAL»(ref-280563-S04690156892008022200000) ). Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and another SST (adaptor). SST 09268-45014 (09268-41200, 09268-41190, 90405-06167, 09268-41210, 90467-11009) Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (Scheme 21): Installing Front Fuel Pipe And SST To Delivery Pipe Wipe off any splattered gasoline. Reconnect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3 (See step 1 in check fuel pump operation). Measure the fuel pressure. Fuel pressure: 265 to 304 kPa (2.7 to 3.1 kgf/cm 2, 38 to 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the following parts: Fuel hoses and connections Fuel pump Fuel filter Fuel pressure regulator Disconnect the intelligent tester from the DLC3. Start the engine. Measure the fuel pressure at idle. Fuel pressure: 265 to 304 kPa (2.7 to 3.1 kgf/cm 2, 38 to 44 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 and carefully remove the SST to prevent gasoline from splashing. SST 09268-45014 (09268-41200, 09268-41190, 90405-06167, 09268-41210, 90467-11009) Reinstall the front fuel pipe to the LH delivery pipe (See «INSTALLATION»(ref-280563-S34138527202008022200000) ). Reconnect the negative (-) terminal cable to the battery. Check for fuel leaks (See step 1 in check fuel pump operation).

Identifying Fuel Injector Components With Torque Specifications (1 Of 2). Scheme 22

Identifying Fuel Injector Components With Torque Specifications (2 Of 2). Scheme 23

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1. DISCHARGE FUEL SYSTEM PRESSURE HINT: (See «FUEL SYSTEM»(ref-280563-S42721263222008022200000) )
2. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY Remove the 2 cap nuts and throttle body cover sub-assembly.
3. REMOVE AIR CLEANER HOSE ASSEMBLY Disconnect the vacuum hoses (for the P/S idle-up and fuel pressure regulator) and ventilation hose. Remove the air cleaner hose assembly.
4. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY Remove the 2 union bolts and 4 gaskets. Remove the bolts and fuel pipe sub-assembly.
5. SEPARATE NO. 3 FUEL PIPE SUB-ASSEMBLY Remove the No. 2 fuel pipe clamp. Remove the 3 bolts and disconnect the fuel return pipe sub-assembly from the fuel pressure regulator. HINT: Move it aside to secure more work space. (Scheme 24): Locating Fuel Return Pipe Sub-Assembly Bolts
6. DISCONNECT FUEL HOSE Remove the pulsation damper and 2 gaskets. Disconnect the No. 1 fuel hose. (Scheme 25): Removing Pulsation Damper
7. SEPARATE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Remove the bolts and separate the vacuum switching valve assembly from the intake manifold.
8. DISCONNECT ENGINE WIRE Disconnect the 8 fuel injector connectors. Remove the 3 bolts and disconnect the engine wire.
9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Remove the 2 nuts, and then the fuel delivery pipe by holding both ends and pulling it straight upward.
10. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY Remove the 2 nuts, and then the No.2 fuel delivery pipe by holding both ends and pulling it straight upward.
11. REMOVE FUEL INJECTOR ASSEMBLY Remove the injector from the delivery pipe. NOTE: Do not apply any force to the injector in the horizontal direction because the O-ring might be stuck. Remove the O-ring, grommet and insulator from the injector.

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1. INSPECT FUEL INJECTOR ASSEMBLY Inspect the injector resistance. Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 13.4 to 14.2 ohms at 20°C (68°F) If the resistance is not as specified, replace the injector. Inspect the injector. CAUTION: Avoid any sparks or flame during the test. (Scheme 26): Inspecting Injector Obtain a new fuel main hose (part No. 23271-50190) and take the fuel tube connector out of the hose. (Scheme 27): Identifying Fuel Tube Connector Install the fuel tube connector to SST (hose), then connect the tube connector and fuel pipe. SST 09268-31011 (95336-08070) CAUTION: Observe the precautions when connecting the fuel tube connector (quick type). (Scheme 28): Installing Fuel Tube Connector To SST 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 09268-31011 (95336-08070, 09268-41091) Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) (Scheme 29): Connecting Fuel Return Hose To Fuel Outlet Of Pressure Regulator Connect the fuel return hose to the fuel outlet of the pressure regulator. Install the O-ring to the injector. (Scheme 30): Installing O-Ring To Injector Connect SSTs (union and hose) to the injector, and hold the injector and union with another SST (clamp). SST 09268-31011 (09268-41110, 09268-41300, 95336-08070) Put the injector into a graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out. Operate the fuel pump (See «ON-VEHICLE INSPECTION»(ref-280563-S37229840922008022200000) ). Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 56 to 69 cm 3 (3.4 to 4.2 cu in.) per 15 seconds Difference between each injector: 13 cm 3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector. (Scheme 31): Connecting SST (Wire) To Injector And Battery Check for leakage. In the condition above, disconnect the tester probes of the SST (wire) from the battery and check for fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 12 minutes (Scheme 32): Checking For Leakage

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1. INSTALL FUEL INJECTOR ASSEMBLY Install a new grommet and insulator to the injector. (Scheme 33): Identifying Grommet And Insulator Check that there is no foreign object or damage to the groove of the O-ring of the injector. Apply gasoline to a new O-ring, and install it to the injector. Install the injector to the delivery pipe while turning the injector in both ways. Check that the injector can turn smoothly. NOTE: When the injector cannot turn smoothly, the O-ring might be caught in something. In that case, replace the O-ring with a new one.
2. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY Install the injector with the delivery pipe to the intake manifold. Turn the injector in both ways by approximately 45 degrees. Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Install the injector with the delivery pipe to the intake manifold. Turn the injector in both ways by approximately 45 degrees. Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
4. INSTALL FUEL HOSE Using 2 new gaskets, install the fuel main hose with the fuel pressure pulsation damper. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (Scheme 34): Identifying Fuel Pressure Pulsation Damper
5. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
6. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf)
7. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY Install the fuel pipe sub-assembly with the bolts. Using 4 new gaskets, install the No. 1 fuel pipe sub-assembly with the 2 union bolts. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
8. INSTALL AIR CLEANER HOSE ASSEMBLY
9. CHECK FOR FUEL LEAKAGE (See «ON-VEHICLE INSPECTION»(ref-280563-S37229840922008022200000) )
10. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf)

Identifying Fuel Pump Components. Scheme 35