Engine Fuel System (2TR-FE): Overview Toyota Tacoma II

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1. PRECAUTION Before working on the fuel system, disconnect the cable from the negative battery terminal. Do not work on the fuel system near fire. Never smoke during the work. Keep rubber and leather parts away from gasoline.
2. DISCHARGE FUEL PRESSURE CAUTION: Before removing fuel system parts, take precautions to prevent gasoline spillage. As some pressure remains in the fuel line even after taking precautions to prevent gasoline spillage, use a shop rag to prevent gasoline splashes when disconnecting the fuel line. Disconnect the cable from the negative battery terminal. Remove the engine relay block cover. Remove the circuit opening relay. Connect the cable to the negative battery terminal. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) Start the engine. Turn the ignition switch to ON after the engine stops. HINT: DTC P0171 (system to lean) may be present. Crank the engine again, and check that the engine stops. Remove the fuel tank cap, and discharge the pressure in the fuel tank completely. Install the circuit opening relay.
3. FUEL SYSTEM When disconnecting the high-pressure fuel line, a large amount of gasoline will splash. So take the following precautions. Discharge the fuel system pressure (step 2 ). Disconnect the fuel tank main tube (see «REMOVAL»(ref-263649-S03550534122007091100000) ). Drain the fuel remaining in the fuel tank main tube. Cover the disconnected fuel tank main tube (fuel tube joint and fuel tube connector) with a vinyl bag to prevent damage and the intrusion of foreign objects. Take the following precautions when installing the fuel injector. Do not reuse the O-ring. Do not damage a new O-ring when installing it onto the fuel injector. Before installing a new O-ring, apply gasoline or spindle oil. NOTE: Do not use engine oil, gear oil or brake oil. Install the fuel injector into the fuel delivery pipe and cylinder head (Scheme 76) HINT: Apply gasoline or spindle oil to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector. Take the following precautions when disconnecting the fuel tube connector. HINT: The structure of the fuel tube connector is (Scheme 77) Check the fuel tube connector and pipe for dirt and mud before removing the fuel tube connector. If dirty, wipe it with a shop rag. Pinch the retainer (Scheme 78), then pull the fuel tube connector out of the pipe. If the fuel tube connector and pipe are stuck, pinch the pipe and push and pull the fuel tube connector to release it. NOTE: Never use any tools. After disconnecting the fuel tube, check the sealing surface of the pipe for dirt and mud. If dirty, wipe it with a shop rag. Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects. Take the following precautions when installing the fuel tube connector. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound. After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.

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1. CHECK FUEL PUMP Connect the intelligent tester to the DLC3. Turn the ignition switch to ON. NOTE: Do not start the engine. Turn the intelligent tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. Check the fuel operation by operating it with the intelligent tester. If the fuel pump does not operate, replace the fuel pump.
2. CHECK FUEL PRESSURE Discharge the fuel system pressure. Using a voltmeter, measure the battery voltage. Standard: 9.0 to 14 V Disconnect the cable from the negative battery terminal. Remove the fuel pipe clamp. Disconnect the fuel hose. Install SST into the vehicle. SST 09268-41048 (09268-41500, 90467-13001, 95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) Wipe off any spilt gasoline. Connect the cable to the negative battery terminal. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 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. Measure the fuel pressure. Standard: 281 to 287 kPa (2.87 to 2.93 kgf/cm 2 , 40.8 to 41.7 psi) If the pressure is too high, replace the fuel pressure regulator. If the pressure is too low, check the connection between the fuel hose and fuel pump. Disconnect the intelligent tester from the DLC3. Start the engine. Measure the fuel pressure while the engine idles. Standard: 281 to 287 kPa (2.87 to 2.93 kgf/cm 2 , 40.8 to 41.7 psi) Stop the engine. Check that the fuel pressure does not change for 5 minutes. Standard: 147 kPa (1.5 kgf/cm 2 , 21 psi) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injector. Discharge the fuel system pressure. Disconnect the cable from the negative battery terminal. Remove SST while being careful to prevent gasoline splashes. Connect the fuel hose. Install the fuel pipe clamp. Connect the cable to the negative battery terminal. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
3. CHECK FOR FUEL LEAKAGE Connect the intelligent tester to the DLC3. Turn the ignition switch to ON. NOTE: Do not start the engine. Turn the intelligent tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD / ON. Check that there are no leakage in the fuel system.

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «FUEL SYSTEM»(ref-263649-S38722706092007091100000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
4. DRAIN ENGINE COOLANT (See «COOLANT»(/toyota/tacoma/ii-2004-2011/remont/cooling-fan/#engine-cooling-system-2tr-fe) )
5. REMOVE INTAKE AIR CONNECTOR (See «REMOVAL»(/toyota/tacoma/ii-2004-2011/remont/testing-diagnostics/#engine-control-system-2tr-fe) )
6. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY (See «REMOVAL»(/toyota/tacoma/ii-2004-2011/remont/testing-diagnostics/#engine-control-system-2tr-fe) )
7. DISCONNECT FUEL HOSE Pull the checker of the fuel hose upward. Pinch the detaching switch of the fuel hose connector and pull out the fuel hose. NOTE: Remove any dirt and foreign objects on 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 hose. If the fuel tube connector and pipe are stuck, push and pull to release them.
8. DISCONNECT NO. 2 FUEL HOSE Pull the checker of the fuel hose upward. Pinch the detaching switch of the fuel hose connector and pull out the fuel hose. NOTE: Remove any dirt and foreign objects on 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 hose. If the fuel tube connector and pipe are stuck, push and pull to release them.
9. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See «FUEL PRESSURE PULSATION DAMPER»(ref-263649-S11712390142007091100000) )
10. REMOVE FUEL DELIVERY PIPE WITH INJECTOR Disconnect the 4 injector connectors. Disconnect the VSV connector. Disconnect the engine wire harness clamp. Disconnect the compressor magnetic clutch connector. (with AIR CONDITIONING) Disconnect the wire harness clamp. Remove the bolt, then remove the harness clamp bracket. Remove the 2 bolts, then remove the fuel delivery pipe together with the fuel injectors. NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe. Remove the 2 delivery pipe No. 1 spacers. Remove the 4 injector vibration insulators. Using a screwdriver, remove the 4 spacers.
11. REMOVE FUEL INJECTOR ASSEMBLY Pull the 4 fuel injectors out of the fuel delivery pipe.

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1. INSPECT FUEL INJECTOR ASSEMBLY Check the resistance. Using an ohmmeter, measure the resistance between the terminals. Resistance: 11.6 to 12.4 ohms at 20°C (68°F) If the result is not as specified, replace the fuel injector. Check the injection volume. CAUTION: This test involves high-pressure fuel and electricity, therefore, safety precautions should be taken. Perform this test in a safe area and avoid any sparks and flames. Do not smoke. Discharge the fuel system pressure (see «PRECAUTION»(ref-263649-S28906504362007091100000) ). Remove the fuel hose from the fuel pressure pulsation damper (see «REMOVAL»(ref-263649-S39494261432007091100000) ). Remove the fuel hose from the fuel pipe (see «FUEL SYSTEM»(ref-263649-S38722706092007091100000) ). Separate the pressure regulator (see «FUEL PRESSURE REGULATOR»(ref-263649-S26162242152007091100000) ). NOTE: Do not separate the fuel hose No.2. Assemble SST (Scheme 100) SST 09268-41048 (09268-41091, 09268-41110, 09268-41120, 09268-41500, 95336-08070, 90467-13001) Connect SST to the fuel pipe. SST 09268-41048 (09268-41500, 90467-13001) Install the pressure regulator onto SST (union) with the 2 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) SST 09268-41048 (09268-41091) NOTE: Make sure that the O-ring is installed onto the pressure regulator. Install the O-ring onto the injector. Assemble SST (Scheme 103) SST 09268-41048 (09268-41110, 09268-41310) Put the injector into a graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to contain any gasoline spray. Make sure that SST is installed (Scheme 104) Operate the fuel pump (see «ON-VEHICLE INSPECTION»(ref-263649-S08722986742007091100000) ). Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30080 Volume: 71 to 86 cm 3 (4.3 to 5.2 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. Check the leakage. In the condition above, disconnect the tester probes of SST (wire) from the battery and check the fuel leakage from the injector. Fuel drop: 1 drop or less in 12 minutes

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1. INSTALL FUEL INJECTOR ASSEMBLY Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each fuel injector. Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the O-ring of the fuel injector. Apply a light coat of gasoline or spindle oil to the O-ring again, then install the fuel injector into the fuel delivery pipe by turning it right and left. NOTE: Make sure that the O-ring is not cracked or jammed when installing. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring.
2. INSTALL FUEL DELIVERY PIPE W/ INJECTOR Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each spacer. Install the 4 spacers onto the cylinder head. Install 4 new injector vibration insulators onto the cylinder head. Install the 2 delivery pipe No. 1 spacers onto the cylinder head. Install the fuel delivery pipe together with the 4 fuel injectors, then provisionally tighten the fuel delivery pipe with the 2 bolts. NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring. Retighten the 2 bolts to the specified torque. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Install the harness clamp bracket with the bolt. Torque: 8.2 N*m (84 kgf*cm, 73 in.*lbf) Connect the wire harness clamp. Connect the compressor magnetic clutch connector. (with AIR CONDITIONING) Connect the engine wire harness clamp. Connect the VSV connector. Connect the 4 injector connectors.
3. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See «FUEL PRESSURE PULSATION DAMPER»(ref-263649-S11712390142007091100000) )
4. CONNECT FUEL HOSE Align the fuel hose connector with the pipe stem, and insert the fuel hose until the retainer makes a "click" sound. Push down the checker of the fuel hose. NOTE: Check that there are no scratches or foreign objects around the disconnected parts of the fuel hose connector and pipe before performing this work. After connecting the fuel hose, check that the fuel hose is securely connected by pulling the fuel hose connector and pipe. Push the fuel hose down until the checker of the fuel hose makes a "click" sound.
5. CONNECT FUEL HOSE NO.2 Align the fuel hose connector with the pipe stem, and insert the fuel hose until the retainer makes a "click" sound. Push down the checker of the fuel hose. NOTE: Check that there are no scratches or foreign objects around the disconnected parts of the fuel hose connector and pipe before performing this work. After connecting the fuel hose, check that the fuel hose is securely connected by pulling the fuel hose connector and pipe. Push the fuel hose down until the checker of the fuel hose makes a "click" sound.
6. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY (See «INSTALLATION»(/toyota/tacoma/ii-2004-2011/remont/testing-diagnostics/#engine-control-system-2tr-fe) )
7. INSTALL INTAKE AIR CONNECTOR (See «INSTALLATION»(/toyota/tacoma/ii-2004-2011/remont/testing-diagnostics/#engine-control-system-2tr-fe) )
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
9. ADD ENGINE COOLANT (See «COOLANT»(/toyota/tacoma/ii-2004-2011/remont/cooling-fan/#engine-cooling-system-2tr-fe) )
10. CHECK FOR ENGINE COOLANT LEAKAGE (See «ON-VEHICLE INSPECTION»(/toyota/tacoma/ii-2004-2011/remont/cooling-fan/#engine-cooling-system-2tr-fe) )
11. CHECK FOR FUEL LEAKAGE (See «ON-VEHICLE INSPECTION»(ref-263649-S08722986742007091100000) )
12. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «FUEL SYSTEM»(ref-263649-S38722706092007091100000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE INTAKE AIR CONNECTOR (See «REMOVAL»(/toyota/tacoma/ii-2004-2011/remont/testing-diagnostics/#engine-control-system-2tr-fe) )
4. DISCONNECT NO. 2 FUEL HOSE (See «REMOVAL»(ref-263649-S18814165612007091100000) )
5. REMOVE FUEL PRESSURE REGULATOR Disconnect the throttle with motor body connectors. Disconnect the VSV connector. Disconnect the engine wire harness clamp. Remove the bolt, then remove the harness clamp bracket. Remove the 3 bolts, then remove the fuel pressure regulator.

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1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY Apply a light coat of gasoline or spindle oil to the O-ring. Install the fuel pressure regulator with the 3 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Install the harness clamp bracket with the bolt. Torque: 8.2 N*m (84 kgf*cm, 73 in.*lbf) Connect the engine wire harness clamp. Connect the VSV connector. Connect the throttle with motor body connectors.
2. CONNECT NO. 2 FUEL HOSE (See «INSTALLATION»(ref-263649-S13229750922007091100000) )
3. INSTALL INTAKE AIR CONNECTOR (See «INSTALLATION»(/toyota/tacoma/ii-2004-2011/remont/testing-diagnostics/#engine-control-system-2tr-fe) )
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
5. CHECK FOR FUEL LEAKAGE (See «ON-VEHICLE INSPECTION»(ref-263649-S08722986742007091100000) )

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «FUEL SYSTEM»(ref-263649-S38722706092007091100000) )
2. DISCONNECT FUEL HOSE (See «REMOVAL»(ref-263649-S18814165612007091100000) )
3. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY Remove the 2 bolts, then remove the fuel pressure pulsation damper.

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1. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Apply a light coat of gasoline or spindle oil to the O-ring. Install the fuel pressure pulsation damper with the 2 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
2. CONNECT FUEL HOSE (See «INSTALLATION»(ref-263649-S13229750922007091100000) )
3. CHECK FOR FUEL LEAKAGE (See «ON-VEHICLE INSPECTION»(ref-263649-S08722986742007091100000) )

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See also:
• COOLANT
• REMOVAL