Sfi System (2UZ-FE): Removal & Installation Toyota Tundra I рестайлинг

REMOVAL

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1. REMOVE FUEL TANK (See «FUEL TANK AND LINE»(ref-181796-S09803920712006080100000) )
2. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
3. DISCONNECT FUEL MAIN TUBE AND RETURN TUBE FROM SUCTION PLATE (See «PRECAUTION»(ref-181796-S31943288342005080400000) )
4. REMOVE FUEL PUMP, SENDER GAUGE AND SUCTION PLATE ASSEMBLY FROM FUEL TANK Remove the 8 bolts. Remove the fuel pump, sender gauge and suction plate assembly. NOTE: Do not damage the fuel pump filter. Be careful not to bend the arm of the sender gauge. Remove the gasket from the fuel suction plate.
5. REMOVE FUEL PUMP FROM SUCTION PLATE Disconnect the lead wire connector from the fuel pump. Pull out the lower side of the fuel pump from the suction plate. Disconnect the fuel hose from the fuel pump, and remove the fuel pump. Remove the rubber cushion from the fuel pump.
6. REMOVE FUEL PUMP FILTER FROM FUEL PUMP Using a small screwdriver, pry out the clip. Pull out the pump filter.

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1. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.2 - 3.0 ohms at 20°C (68°F) If the resistance is not as specified, replace the fuel pump.
2. INSPECT FUEL PUMP OPERATION Connect the lead wire to the fuel pump. Connect the positive (+) lead from the battery to terminal 1 of the connector, and the negative (-) lead to terminal 2. Check that the fuel pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. Always do switching at the battery side. If operation is not as specified, replace the fuel pump and/or read wire. Disconnect the lead wire to the fuel pump.

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1. INSTALL FUEL PUMP FILTER TO FUEL PUMP Using a small screwdriver, push in the clip.
2. INSTALL FUEL PUMP TO SUCTION PLATE Install the rubber cushion to the fuel pump. Connect the fuel hose to the outlet port of the fuel pump. Install the fuel pump by pushing the lower side of the fuel pump. Connect the lead wire connector to the fuel pump.
3. INSTALL FUEL PUMP, SENDER GAUGE AND SUCTION PLATE ASSEMBLY TO FUEL TANK Install a new gasket to the suction plate. Insert the fuel pump, sender gauge and suction plate assembly into the fuel tank. Install the suction plate with the 8 bolts. Torque: 3.5 N.m (35 kgf.cm, 31 in.lbf)
4. CONNECT FUEL MAIN TUBE AND RETURN TUBE TO SUCTION PLATE (See «PRECAUTION»(ref-181796-S31943288342005080400000) )
5. CONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
6. INSTALL FUEL TANK (See «FUEL TANK AND LINE»(ref-181796-S09803920712006080100000) )
7. CHECK FOR FUEL LEAKS (See «PRECAUTION»(ref-181796-S31943288342005080400000) )

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1. REMOVE FUEL PRESSURE REGULATOR Disconnect the vacuum hose from intake air resonator. Disconnect the fuel return hose from the pressure regulator. CAUTION: Put a shop towel under the pressure regulator. Remove the 2 bolts, and pull out the pressure regulator. Remove the O-ring from the pressure regulator.
2. REINSTALL FUEL PRESSURE REGULATOR Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. While turning the pressure regulator left and right, install it to the delivery pipe. Install the pressure regulator with the 2 bolts. Torque: 7.5 N.m (80 kgf-cm, 66 in.lbf) Connect the vacuum hose to intake air resonator. Connect the fuel return hose to the pressure regulator.
3. CHECK FOR FUEL LEAKS (See «PRECAUTION»(ref-181796-S31943288342005080400000) )

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1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. INSPECT INJECTOR RESISTANCE Disconnect the 8 injector connectors. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 - 14.2 ohms. at 20°C (68°F) If the resistance is not as specified, replace the injector. Reconnect the 8 injector connectors.
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER

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1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. REMOVE FUEL PRESSURE PULSATION DAMPER Remove the pulsation damper, upper gasket, fuel main hose and lower gasket. CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the pulsation damper.
4. DISCONNECT PCV HOSE FROM PCV VALVE
5. DISCONNECT VSV FOR EVAP Disconnect the VSV connector. Disconnect the EVAP hose. Disconnect the VSV from the intake manifold.
6. REMOVE LH THROTTLE BODY COVER BRACKET Remove the bolt and cover bracket.
7. DISCONNECT ENGINE WIRES Disconnect the engine wire clamps from the No. 1 engine hanger and engine wire bracket. Disconnect the 2 wire clamps on the engine wire from the brackets on the RH delivery pipe.
8. REMOVE DELIVERY PIPES AND INJECTORS NOTE: Be careful not to drop the injectors when removing the delivery pipes. Pay attention to put any hung load on the injector to and from the side direction. Remove the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Remove the bolt, 2 union bolts, 4 gaskets and front fuel pipe. Disconnect the 8 injector connectors. Remove the 4 nuts holding the delivery pipes to the lower intake manifold. Remove the 2 delivery pipes, 8 injectors, 4 spacers and 8 insulators. Remove the O-ring and grommet from each injector.

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1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. Disconnect the fuel inlet hose (fuel tube connector) from the fuel filter. Connect SST (attachment and hose) to the fuel tube. SST 09268-41047 (09268-52011) Remove the pressure regulator from the delivery pipe. Install the O-ring to the fuel inlet of the pressure regulator. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268-41047 (09268-1091) 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 SST (adaptor and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41047 (09268-41110, 09268-1300) Put the injector into the graduated cylinder. CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. Connect a hand-held tester to the DLC3. Connect the battery negative (-) cable to the battery. Turn the ignition switch ON, and push the hand-held tester main switch ON. NOTE: Do not start the engine. Select the ACTIVE TEST mode on the hand-held tester. Please refer to the hand-held tester operator's manual for further details. Connect 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 09842-30070 Volume: 56 - 69 cm 3 (3.4 - 4.2 cu in.) per 15 sec. Difference between each injector: 13 cm 3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE In the condition above, disconnect the tester probes of SST (wire) from the battery and check the fuel leakage, from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 12 min. Turn the ignition switch OFF. Disconnect the negative (-) terminal cable from the battery. Remove the SST and fuel tube connector. SST 09268-1047, 09842-30070 Disconnect the hand-held tester from the DLC3. Reconnect the fuel inlet pipe to the fuel tube.

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1. INSTALL INJECTORS AND DELIVERY PIPES NOTE: Be careful not to drop the injectors when installing the delivery pipes. Pay attention to put any hung load on the injector to and from the side direction. Install a new grommet to each injector. Apply a light coat of gasoline to a new O-rings and install it to each injector. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 8 injectors. Position injector connector outward. Place the 4 spacers and 8 new insulators on the intake manifold. Place the 2 delivery pipes and injectors assemblies on the lower intake manifold. Temporarily install the 4 nuts. Install the front fuel pipe with the bolt, 4 new gaskets and 2 union bolts. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) for union bolts 7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt Install the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings. Position injector connector outward. Tighten the 4 nuts holding the delivery pipes to the lower intake manifold. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Connect the 8 injectors connectors.
2. INSTALL ENGINE WIRES Install the 2 wire clamps on the engine wire to the brackets on the RH delivery pipe. Connect the engine wire clamps to the No. 1 engine hanger and engine wire bracket. Install the engine wire protector with the 2 bolts.
3. CONNECT PCV HOSE TO PCV VALVE
4. CONNECT VSV FOR EVAP TO UPPER INTAKE MANIFOLD Install the VSV to the upper intake manifold. Connect the EVAP hose. Connect the VSV connector.
5. INSTALL THROTTLE BODY COVER BRACKET Install the cover bracket with the bolt.
6. INSTALL FUEL PRESSURE PULSATION DAMPER (See «PRECAUTION»(ref-181796-S31943288342005080400000) )
7. INSTALL INTAKE AIR CONNECTOR
8. INSTALL THROTTLE BODY COVER

REPLACEMENT

Note. Be care not to give a shock to the throttle body. Be care not to disassemble the throttle body.

1. REMOVE THROTTLE BODY COVER
2. DRAIN ENGINE COOLANT
3. REMOVE INTAKE AIR CONNECTOR
4. REMOVE THROTTLE BODY Disconnect the throttle position sensor & throttle control motor connector. Disconnect the PCV hose and water bypass hose from the throttle body. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. Disconnect the water bypass hose from the throttle body, and remove the throttle body. Remove the gasket.
5. REINSTALL THROTTLE BODY Connect the water bypass hose to the throttle body. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Connect the water bypass hose and PCV hose to the throttle body. Connect the throttle position sensor & throttle control motor connector.
6. INSTALL INTAKE AIR CONNECTOR
7. REFILL WITH ENGINE COOLANT (See «COOLANT - 2UZ-FE»(ref-181803) )
8. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS
9. REINSTALL THROTTLE BODY COVER

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1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY Inspect the 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. Inspect the 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
5. REINSTALL RELAY BOX COVER

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1. REMOVE RELAY BOX COVER
2. REMOVE CIRCUIT OPENING RELAY (Marking: C/OPN)
3. INSPECT CIRCUIT OPENING RELAY Inspect the 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. Inspect the relay operation. Apply battery positive voltage across terminals 1 and 2. Using an ohmmeter, check that there is continue between terminals 3 and 5. If there is no continuity, replace the relay.
4. REINSTALL CIRCUIT OPENING RELAY
5. REINSTALL RELAY BOX COVER

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1. REMOVE RELAY BOX COVER
2. REMOVE FUEL PUMP RELAY (Marking: F/PMP)
3. INSPECT FUEL PUMP RELAY Inspect the 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 continuity between terminals 3 and 4. 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. Inspect the relay operation. Apply battery positive voltage across terminals 1 and 2. Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. Check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay.
4. REINSTALL FUEL PUMP RELAY
5. REINSTALL RELAY BOX COVER

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1. REMOVE FUEL PUMP RESISTOR
2. INSPECT FUEL PUMP RESISTOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.70 - 0.76 ohms at 20°C (68°F) If the resistance is not as specified, replace the resistor.
3. REINSTALL FUEL PUMP RESISTOR Torque: 8 N.m (82 kgf.cm, 71 in.lbf)

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1. REMOVE VSV
2. INSPECT VSV Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 26 - 30 ohms at 20°C (68°F) If there is no continuity, replace the VSV. 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. Inspect the VSV operation. Check that air dose not flow from ports. Apply battery positive voltage across the terminals. Check that air flows from ports. If operation is not as specified, replace the VSV.
3. 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: RESISTANCE CHART 20°C (68°F) 25 - 30 ohms 100°C (212°F) 32 - 42 ohms If there is no continuity, replace the VSV.
3. INSPECT VSV OPERATION Check that air flows from ports A to B and C. Apply battery positive voltage across the terminals. Check that the valve is closed. Check that air does not flow from ports A to B. Check that air flows from ports A to C. If operation is not as specified, replace the VSV.
4. REINSTALL VSV

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1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. Remove the gasket.
5. REMOVE ECT SENSOR Disconnect the ECT sensor connector. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR Install a new gasket and the ECT sensor. Torque: 19.6 N.m (200 kgf.cm, 14 ft.lbf) Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT (See «COOLANT - 2UZ-FE»(ref-181803) )
11. REINSTALL THROTTLE BODY COVER

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1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V Turn the ignition switch OFF.
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 FUEL TANK (See «FUEL TANK AND LINE»(ref-181796-S09803920712006080100000) )
2. REMOVE VAPOR PRESSURE SENSOR Slightly turn the sensor. Remove the joint clip. Pull out the sensor. Plug the port of the fuel suction plate with a clean rubber cap.
3. REINSTALL VAPOR PRESSURE SENSOR Attach the sensor to the port of the fuel suction plate. Install the joint clip. Turn the sensor, and face the sensor connector forward.
4. REINSTALL FUEL TANK (See «FUEL TANK AND LINE»(ref-181796-S09803920712006080100000) )

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1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS (See «INSPECTION»(ref-181796-S22463201242006080100000) )
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY (See «CYLINDER HEAD (2UZ-FE)»(ref-181791) )
5. INSPECT KNOCK SENSORS Disconnect the knock sensor connectors. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY (See «CYLINDER HEAD (2UZ-FE)»(ref-181791) )
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS (See «INSPECTION»(ref-181796-S22463201242006080100000) )
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER

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1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS Disconnect the sensor connector. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: RESISTANCE CHART 20°C (68°F) 11 - 16 ohms 800°C (1,472°F) 23 - 32 ohms If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2 Reconnect the sensor connector.
2. INSPECT OPERATION OF HEATED OXYGEN SENSORS (See «DTC P0130: OXYGEN SENSOR CIRCUIT (BANK 1 SENSOR 1)»(ref-181813-S32210917432005080400000) and «DTC P0136: OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK 2 SENSOR 1)»(ref-181813-S21699525172005080400000) )

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