Sfi System: Removal & Installation Toyota Celica T230 рестайлинг

REMOVAL

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1. REMOVE REAR SEAT CUSHION
2. REMOVE FLOOR SERVICE HOLE COVER
3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR AND VAPOR PRESSURE SENSOR CONNECTOR
4. DISCONNECT FUEL TUBE AND EMISSION TUBE Wash away the mud, dust and the likes on the fuel suction plate with water. Pull off the tube joint clip from the No. 1 fuel suction plate. Disconnect the fuel tube from the fuel pump assembly. Disconnect the emission tube from the fuel pump assembly. Attach the tape in order to protect the port portion from the dust. Protect the disconnected fuel tube from damage and foreign material by covering it with a plastic bag.
5. REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK Remove the 8 bolts and fuel tank vent tube set plate. Pull out the fuel pump assembly. NOTE: Do not damage the fuel pump filter. Be careful that the arm of the send gauge should not bent. Remove the gasket from the pump assembly.

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1. REMOVE NO. 2 FUEL SUCTION SUPPORT Using a small screwdriver, remove the No. 2 fuel suction support. Remove the rubber cushion.
2. REMOVE NO. FUEL SUCTION SUPPORT Disconnect the fuel sender gauge connector and earth plate. While pressing the lock of the fuel pump filter, slide the fuel sender gauge and remove it. Using a small screwdriver, remove the No. 1 fuel suction support. NOTE: Do not damage the fuel suction support and fuel suction plate. Disconnect the fuel pump harness from the No. 1 fuel suction support and fuel pump.
3. REMOVE VAPOR PRESSURE SENSOR Pull off the joint clip and remove the vapor pressure sensor from No. 1 fuel suction support.
4. REMOVE FUEL PUMP Remove the pump from the fuel filter.
5. REMOVE FUEL PRESSURE REGULATOR Pull out the fuel pressure regulator and O-ring from the fuel filter.
6. REMOVE FUEL SUCTION FILTER Using a small screwdriver, pry out the clip. Pull out the suction filter.

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1. INSTALL FUEL SUCTION FILTER Install the suction filter with a new clip.
2. INSTALL FUEL PUMP Connect the fuel pump to the fuel filter.
3. INSTALL FUEL PRESSURE REGULATOR Install the O-ring to the pressure regulator. HINT: Apply a light coat of gasoline to a new O-ring, and install it to the pressure regular. Connect the pressure regulator to the fuel filter.
4. INSTALL NO. 1 FUEL SUCTION SUPPORT Connect the fuel pump harness to the No. 1 fuel suction support and fuel pump. Install the No. 1 fuel suction support to the fuel filter. Install the fuel sender gauge to the fuel pump filter so that the distance between the No. 1 fuel suction support and the float fulcrum of the fuel sender gauge is 150 mm (5.91 in.). Connect the fuel sender gauge connector and earth plate.
5. INSTALL NO. 2 FUEL SUCTION SUPPORT Install the rubber cushion. Install the No. 2 fuel suction support to the No. 1 fuel suction support.
6. INSTALL VAPOR PRESSURE SENSOR Install vapor pressure sensor and connect the joint clip to the No. 1 fuel suction support.

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1. INSTALL FUEL PUMP ASSEMBLY Install the new gasket to the fuel pump assembly. Install the fuel pump assembly to the fuel tank. NOTE: Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should not bent. Install the 8 bolts and fuel tank vent tube set plate from the fuel tank. Torque: 4.0 N.m (40 kgf.cm, 35 in..lbf)
2. CONNECT FUEL TUBE Clean up around the fuel tube. Connect the fuel tube and emission tube to the fuel pump assembly. Connect the tube joint clip to the fuel suction plate.
3. CONNECT FUEL PUMP AND SENDER GAUGE CONNECTOR AND VAPOR PRESSURE SENSOR CONNECTOR HINT: Start the engine, check for fuel leakage.
4. INSTALL FLOOR SERVICE HOLE COVER Install the service hole cover. Install the floor carpet.
5. INSTALL REAR SEAT CUSHION

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1. REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK (See «REMOVAL»(ref-206126-S34540656692006062000000) )
2. REMOVE NO. 1 FUEL SUCTION SUPPORT (See «DISASSEMBLY»(ref-206126-S31341581022006062000000) )
3. REMOVE FUEL PRESSURE REGULATOR Pull out the pressure regulator. Remove the O-ring from the pressure regulator.

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1. INSTALL FUEL PRESSURE REGULATOR Install the O-ring to the pressure regulator. HINT: Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. Connect the pressure regulator from the fuel filter.
2. INSTALL NO. 1 FUEL SUCTION SUPPORT (See «REASSEMBLY»(ref-206126-S18389952902006062000000) )
3. INSTALL FUEL PUMP ASSEMBLY TO FUEL TANK (See «INSTALLATION»(ref-206126-S28863625532006062000000) )

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1. REMOVE NO. 2 CYLINDER HEAD COVER
2. CHECK OPERATION SOUND FROM EACH INJECTOR Connect the PCV hose to cylinder head cover. With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. If you have no sound scope, you can check the injector transmission operation with your finger. If no sound or unusual sound is heard, check the wiring connector, injector signal from the ECM. Disconnect the PCV hose from cylinder head cover.
3. INSPECT INJECTOR RESISTANCE Disconnect the injector connector. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 - 14.2 ohm at 20°C (68°F) If the resistance is not as specified, replace the injector. Reconnect the injector connector.
4. INSTALL WIRE HARNESS PROTECTOR COVER Install the wire harness protector cover with bolt and 2 nuts. Connect the PCV hose to cylinder head cover.

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1. REMOVAL NO. 2 CYLINDER HEAD COVER
2. 1ZZ-FE: REMOVE PCV HOSE
3. DISCONNECT FUEL TUBE Remove the fuel pipe clamp. Disconnect the fuel tube (fuel tube connector) from the fuel pipe. CAUTION: Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment.
4. REMOVE DELIVERY PIPE AND INJECTORS NOTE: Be careful not to drop the injectors when removing the delivery pipe. Disconnect the 4 injector connectors from injector. Remove the 3 bolts and delivery pipe together with the 4 injectors and fuel pipe. Remove the 2 spacers from the cylinder head. Pull out the 4 injectors from the delivery pipe. Remove the O-ring and grommet from each injector.

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1. INSPECT INJECTOR INSPECTION CAUTION: Keep injector clear of sparks during the test. Purchase the new fuel tube and take out the fuel tube connector from its pipe. Part No. 23901-22010 Connect SST (hose) and fuel tube connector to the fuel pipe. SST 09268-41047 CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. Install the grommet and O-ring to the injector. Connect SST (union and hose) to the injector, and hold the injector to prevent gasoline from splashing out. SST 09268-41047 Put the injector into a graduated cylinder. HINT: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out. Connect the TOYOTA hand-held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. Select the active test mode on the TOYOTA hand-held tester. Please refer to the TOYOTA hand-held tester operators manual for further details. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See «INJECTOR»(ref-206126-S31922676382006062000000) ). Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduate cylinder. Test each injector 2 or 3 times. SST 09842-30080 Volume: 47 - 58 cm 3 (2.7 - 3.3 cu in.) per 15 sec. Difference between each injector: 10 cm 3 (0.6 cu in.) or less If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30080 Fuel drop: 1 drop or less per 12 minutes Turn the ignition switch to LOCK Disconnect the negative (-) terminal cable from the battery. Remove the SST and fuel tube connector. SST 09268-41047 CAUTION: Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. Disconnect the TOYOTA hand-held tester from the DLC3.

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1. INSTALL INJECTORS AND DELIVERY PIPES Install the grommet to each injector. Apply a light coat of spindle oil or gasoline to new O-ring and install them to each injector. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches on O-ring. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 4 injectors. Position the injector connector outward. Place the 2 spacers in position on the cylinder head. Apply a light coat of spindle oil or gasoline on the place where a cylinder head touches an O-ring of the injector. Place the delivery pipe and fuel pipe together with the injectors in position on the cylinder head. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. Temporarily install the bolt holding the fuel pipe to the cylinder head. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-ring. Replace the O-ring. Position the injector connector outward. Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 1ZZ-FE: 19 N.m (190 kgf.cm, 14 ft.lbf) 2ZZ-GE: 29 N.m (290 kgf.cm, 21 ft.lbf) Tighten the bolt holding the fuel pipe to the cylinder head. Torque: 9 N.m (92 kgf.cm, 7 ft.lbf)
2. CONNECT FUEL TUBE Connect the fuel tube (fuel tube connector) to the fuel pipe. CAUTION: Perform connecting operations of the connector (quick type) after observing the precautions. Install the fuel pipe clamp.
3. INSTALL NO. 2 CYLINDER HEAD COVER

REMOVE AIR FLOW METER

Remove the 2 screws, air flow meter and O-ring.

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1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. Resistance: If the resistance is not as specified, replace the MAF meter.
2. INSPECT MAF METER OPERATION Connect the MAF meter connector. Turn the ignition switch to ON. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replaced the MAF meter. Turn the ignition switch LOCK. Disconnect the MAF meter connector.

INSTALLATION

Installation is in reverse order of removal (See REMOVAL ).

HINT

Install the IAC valve with a new gasket.

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1. Remove the No. 2 cylinder head cover.
2. 2ZZ-GE: Disconnect the 2 PCV hoses.
3. Disconnect the oil control valve connector.
4. Using an ohmmeter, measure the resistance between the terminals. Resistance: 6.9-7.9 ohm at 20°C (68°F) If the resistance is not as specified, replace the valve.
5. Reconnect the oil control valve connector.
6. Reinstall the V-bank cover.

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1. REMOVE NO. 2 CYLINDER HEAD COVER
2. 2ZZ-GE: DISCONNECT 2 PCV HOSES, UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL
3. 2ZZ-GE: REMOVE GENERATOR (See «GENERATOR»(ref-164007-S16661196062004072000000) )
4. 2ZZ-GE: REMOVE NO. 1 VENTILATION PIPE Remove the 2 nuts, bolt and gasket. HINT: At the time of installation, please refer to the following items. Use a new gasket. Remove the hose clamp and disconnect No. 1 ventilation pipe.
5. 1ZZ-FE: REMOVE CAMSHAFT TIMING OIL CONTROL VALVE Disconnect the oil control valve connector. Remove the bolt and oil control valve. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf) Remove the O-ring from the oil control valve. HINT: At the time of installation, please refer to the following items. Use a new O-ring.
6. 2ZZ-GE: REMOVE 2 CAMSHAFT TIMING OIL CONTROL VALVES Disconnect the oil control valve connector. Remove the 2 bolts and oil control valves. Torque: 8.5 N.m (87 kgf.cm, 75 in..lbf) Remove the O-ring from the each oil control valve. HINT: At the time of installation, please refer to the following items. Use a new O-ring.

Installation is in the reverse order of removal. (See REMOVAL )

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1. REMOVE EFI MAIN RELAY (Marking: EFI)
2. INSPECT EFI MAIN RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.
3. INSPECT EFI MAIN RELAY OPERATION Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay.
4. REINSTALL EFI MAIN RELAY

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1. REMOVE CIRCUIT OPENING RELAY
2. INSPECT EFI MAIN RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.
3. INSPECT CIRCUIT OPENING RELAY OPERATION Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay.
4. REINSTALL CIRCUIT OPENING RELAY

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1. Inspect the VSV for open circuit. Using an ohmmeter, check that there is no continuity between the terminals. Resistance: 37-44 ohm at 20°C (68°F) If there is no continuity, replace the VSV.
2. Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV.
3. Inspect the VSV operation. Check that air flows from ports E to G. Apply battery positive across the terminals. Check that air flows from ports E to F. If operation is not as specified, replace the VSV.

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1. REMOVE VSV Disconnect the 2 EVAP hoses from the VSV. Disconnect the VSV connector. Remove the bolt and VSV.
2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 27-33 ohm at 20°C (68°F) If there is no continuity, replace the VSV.
3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV.
4. INSPECT VSV OPERATION Check that air flows with difficulty from port E to port F. Apply battery voltage across the terminals. Check that air flows from port E to port F. If operation is not as specified, replace to VSV.
5. REINSTALL VSV Install the VSV with the bolt. Connect the VSV with the bolt. Connect the 2 EVAP hoses to the VSV.

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1. REMOVE VSV
2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: If there is no continuity, replace the VSV.
3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is no continuity, replace the VSV.
4. INSPECT VSV OPERATION Check that air flows from ports A to B. Apply battery positive voltage across the terminals. Check that air does not flow from ports A to B. If operation is not as specified, replace the VSV.
5. REINSTALL VSV

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1. REMOVE VSV
2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: If there is no continuity, replace the VSV.
3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is no continuity, replace the VSV.
4. INSPECT VSV OPERATION Check that air flows from ports E to F. Apply battery positive voltage across the terminals. Check that air does not flow from ports E to F. If operation is not as specified, replace the VSV.
5. REINSTALL VSV

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1. DRAIN ENGINE COOLANT
2. REMOVE NO. 2 CYLINDER HEAD COVER
3. REMOVE ECT SENSOR
4. INSPECT ECT SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals 1 (E2) and 2 (THW). Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor.
5. REINSTALL ECT SENSOR Install a new gasket to the ECT sensor.
6. REINSTALL NO. 2 CYLINDER HEAD COVER
7. FILL RADIATOR WITH ENGINE COOLANT

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1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR Disconnect the vapor pressure sensor connector. HINT: Near the fuel tank. Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals 1 and 3 of the wiring harness side. Voltage: 4.5-5.5 V Turn the ignition switch to LOCK. Reconnect the vapor pressure sensor connector.
2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR Turn the ignition switch ON. Remove the fuel tank cap. Connect a voltmeter to terminals 2 and 3, and measure the output voltage. Voltage: 3.0-3.6 V Reinstall the fuel tank cap.

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1. REMOVE THROTTLE BODY (See «REMOVAL»(ref-206126-S25015568562006062000000) or «REMOVAL»(ref-206126-S15436777132006062000000) )
2. REMOVE RADIATOR RESERVOIR (See «REMOVAL»(ref-206131-S09822937122005112400000) )
3. REMOVE INTAKE MANIFOLD (See «REMOVAL»(ref-163200-S13032368722005020100000) )
4. 1ZZ-FE: REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Using SST, remove the knock sensor. SST 09816-30010
5. 2ZZ-GE: REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the nut and knock sensor.
6. 1ZZ-FE: INSPECT KNOCK SENSOR Using an ohmmeter, check that there is continuity between the terminal and body. If there is continuity, replace the sensor.
7. 2ZZ-GE: INSPECT KNOCK SENSOR Using an ohmmeter, measure the resistance between terminals. Resistance: 120-280 kohm at 20°C (68°F) If the resistance is not specified, replace the sensor.
8. 1ZZ-FE: REINSTALL KNOCK SENSOR Using SST, install the knock sensor. SST 09816-30010 Connect the knock sensor connector.
9. 2ZZ-GE: REINSTALL KNOCK SENSOR Install the knock sensor with the nut. Connect the knock sensor connector.
10. REINSTALL INTAKE MANIFOLD (See «INSTALLATION»(ref-163200-S02167951622005020100000) )
11. REINSTALL RADIATOR RESERVOIR (See «INSTALLATION»(ref-206131-S38333814312005112400000) )
12. REINSTALL THROTTLE BODY (See «REMOVAL»(ref-206126-S25015568562006062000000) or «REMOVAL»(ref-206126-S15436777132006062000000) )

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1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) Disconnect the oxygen sensor connector. Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: 1ZZ-FE: 5-10 ohm at 20°C (68°F) 2ZZ-GE: 11-16 ohm at 20°C (68°F) If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 31 ft.lbf) Reconnect the oxygen sensor connector.
2. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR (BANK 1, SENSOR 2) Remove the passenger's seat. Take out the floor carpet. Disconnect the oxygen sensor connector. Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: 11-16 ohm at 20°C (68°F) If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 31 ft.lbf) Reconnect the oxygen sensor connector. Resistance the floor carpet. Reinstall the passenger's seat.

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