SFI

SF–1 SFI (5S–FE) – SFI SYSTEM

SFI SYSTEM

SF0D6–04

PRECAUTION 1.

BEFORE BEFO RE WORK WORKIN ING G ON FUEL FUEL SYST SYSTEM EM,, DISC DISCON ON-NECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY

HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (–) terminal cable is removed from the battery. Therefore, if necessary, necessary, read the diagnosis before removing the negative (–) terminal cable from the battery. 2. DO NOT NOT SMO SMOKE KE OR WORK WORK NE NEAR AR AN OPEN OPEN FLAM FLAME E WHEN WORKING ON THE FUEL SYSTEM 3. KEEP KE EP GAS GASOL OLIN INE E AW AWAY FRO FROM M RUB RUBBE BER R OR OR LEA LEATH TH-ER PARTS 4. MAINT INTENANCE P PR RECAUTIONS (a) In event event of engin engine e misfi misfire, re, thes these e preca precauti ution ons s should should be taken. (1) Ch Check eck prop proper er conn connect ection ion to batt battery ery termi terminal nals, s, etc. etc. (2) Aft After er repa repair ir work work,, ch check eck tha thatt the the ignit ignition ion coil coil te termi rmi-nals and all other ignition system lines are reconnected securely. (3) When When clean cleanin ing g the the engi engine ne compa compartm rtment ent,, be espeespecially careful to protect the electrical system from water. (b) Precau Precautio tions ns when when handl handling ing the oxyge oxygen n sens sensor or.. (1) Do not not allo allow w oxyg oxygen en sensor sensor to dro drop p or hit hit again against st an an object. (2) Do not allow allow the sensor sensor to come come into into cont contact act with with water. 5. IF VEH VEHIC ICLE LE IS EQUI EQUIPP PPED ED WITH WITH MOBI MOBILE LE RA RADI DIO O SYS SYS-TEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 6. AIR INDUCTION SYSTEM (a) Separa Separatio tion n of the eng engine ine oil dipsti dipstick, ck, oil oil fille fillerr cap, cap, PCV hose, etc. may cause the engine to run out of tune. (b) Discon Disconnec nectio tion, n, loosen looseness ess or or cracks cracks in in the part parts s of the the air air induction system between the throttle body and cylinder head will allow air suction and cause cause the engine to run out of tune. 7. ELECTRONIC CO CONTROL SY SYSTEM (a) Before Before remov removing ing SFI wiri wiring ng con connec nector tors, s, termi terminal nals, s, etc., etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the negative (–) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (–) terminal cable from the battery.

AuthorĂ:

DateĂ:

1434


(b) (c)

(d)

(e) (e) (f)

(g) (h)

When insta installi lling ng the the batt battery ery,, be espe especia cially lly care careful ful n not ot to inincorrectly connect the positive (+) and negative (–) cables. Do not not p perm ermit it part parts s to rece receive ive a sever severe e impac impactt durin during g reremoval or installation. Handle all SFI parts carefully, especially the ECM. Be carefu carefull during during trou trouble blesho shooti oting ng as ther there e are num numero erous us transistor circuit, and even slight terminal contact can cause further troubles. Do not not ope open n the the EC ECM Mc cov over er.. When When inspe inspecti cting ng duri during ng rain rainy y weath weather er,, take take care care to preprevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts Parts should should be replac replaced ed as an assemb assembly ly.. Care Ca re shoul should d be take taken n wh when en p pull ulling ing out out and insert inserting ing wirwiring connectors. (1) (1) Re Rele lease ase the the lock lock and and pull pull out out the con conne necto ctorr, pullin pulling g on the connectors. (2) Fully Fully inser insertt the conne connecto ctorr and and ch chec eck k that that it is is locke locked. d.

(i)

Use SST for inspec inspectio tion no orr ttest est of the inject injector or or its wiring wiring connector. SST 09842–30070

8. (a)

FUEL SYSTEM When When discon disconnec nectin ting g the the high high ffue uell press pressure ure line, line, a large large amount of gasoline will spill out, so observe these procedures: (1) (1) Disc Discon onne nect ct the the fuel fuel pum pump p con conne nect ctor or.. (2) Start Start the the e engi ngine ne.. Af After ter the eng engine ine has has stopp stopped ed on its own, turn the ignition switch OFF.

SST

FI2553

Fuel Pump Connector

S04600

(3) (3) (4) (4) (5) (5) (6) (6) (7) (7)

Plug

Put a con Put conta tain iner er und under er the the conn connec ecti tion on.. Slow Slowly ly loos loosen en the the conn connec ecti tion on.. Disc Discon onne nect ct tthe he conn connec ecti tion on.. Plug Plug the the con conne nect ctio ion n wi with th a rub rubbe berr plug plug.. Reco Re conn nnec ectt the the fuel fuel pum pump p conn connec ecto torr.

S05326

AuthorĂ:

DateĂ:

1435


(b)

When When conne connecti cting ng the the unio union n bolt bolt on on the the high high pres pressur sure e pipe pipe union, observe these procedures: (1) (1) Alwa Always ys use use 2 new new gas gaske kets ts.. (2) (2) Tight ighten en the the uni union on bolt bolt by hand hand.. (3) Tighten ighten the union union bol boltt to the specif specified ied torque torque.. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)

New Gasket S05523

SST

(c)

Fulcrum Length Length 30 cm

FI1654

O–Ring

When When connect connecting ing the the flar flare e nut nut on the high high pres pressur sure e pipe pipe union, observe these procedures: (1) Apply Apply a ligh lightt coat coat of of en engin gine e oil oil to the the fflar lare e nu nut, t, and and tighten the flare nut by hand. (2) (2) Using Using SST SST, tighte tighten n the flar flare e nut to to specif specified ied tor torque que.. SST 09631–22020 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) for using SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

(d) (d)

CORRECT

Injector

Delivery Pipe Grommet WRONG

Observ Observe e these prec precau autio tions ns when when remo removin ving g and inst instal alliling ng the injectors. (1) (1) Ne Neve verr reus reuse e the the O–ri O–ring ng.. (2) When When placin placing g a new new O–ri O–ring ng on the the inje injecto ctorr, ta take ke care not to damage it in any way. (3) Co Coat at a new O–ring O–ring with with spind spindle le oil or gaso gasolin line e be be-fore installing–never use engine, gear or brake oil.

FI0420

AuthorĂ:

DateĂ:

1436


(e)

California O–Ring Insulator Grommet

O–Ring

(f)

Injector

Except California

Instal Installl the injec injector tor to to the delive delivery ry pipe pipe and and cylin cylinder der head head,, as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manmanifold touches an O–ring of the injector. Observ Observe e thes these ep prec recau autio tions ns wh when en discon disconnec nectin ting g the the fue fuell tube connector (quick type): (1) Ch Check eck if ther there e is any dirt dirt like like mu mud d on the pipe pipe a and nd around the connector before disconnecting them and clean the dirt away. (2) (2) Be sure sure to disc discon onne nect ct with with hand hands. s.

O–Ring

Insulator

Grommet Injector

Z11336

(3) Pull

(4)

When When the the conne connecto ctorr and and the the pipe pipe are stuck, stuck, pinch pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect Inspect if ther there e is any any d dir irtt or the the llik ikes es o on n the the seal seal sur sur-face of the disconnected pipe and clean it away.

S04583

(5)

Vinyl Bag

Preven Preventt the discon disconne necte cted dp pipe ipe and and conne connecto ctorr from from damaging and mixing foreign objects by covering them with a vinyl bag.

S05040

(g) Retainer

Observ Observe e these these preca precauti ution ons s wh when en conn connect ectin ing g the the fuel fuel tube connector (quick type): (1) Do not reuse reuse the the reta retaine inerr remov removed ed from from the pipe. pipe. (2) Must use use han hands ds withou withoutt us using ing too tools ls whe when n to remove remove the retainer from the pipe. (3) Ch Check eck ifif there there is any any dama damage ge or or forei foreign gn obj object ects s on the connected part of the pipe.

S05382

AuthorĂ:

DateĂ:

1437


(4)

Click Sound

S05050

(h)

Match Match the axis axis of of the conn connec ecto torr with with axi axis s of the pipe pipe,, and push in the connector until the retainer makes a ”click” sound. In case that the connections is tight, apply little amount of new engine oil on the tip t ip of the pipe. (5) Aft After er havin having g finis finished hed the connec connectio tion, n, chec check k if the pipe and the connector are securely connected by pulling them. (6) (6) Ch Chec eck k ifif the there re is any any fue fuell lea leaka kage ge.. Observ Observe e th these ese precau precautio tions ns when when han handli dling ng nylo nylon n tu tube. be. (1) Pay attent attention ion not to turn turn the conne connecte cted d pa part rt of of the the nylon tube and the quick connector with force when connecting them. (2) (2) Pa Pay y at atte tent ntio ion n not not to kin kink k th the e ny nylo lon n tube tube.. (3) Do not not remo remove ve the the EPDM EPDM prot protect ector or on the out outsid side e of the nylon tube. (4) Must Must not not close close the piping piping with with the the nylo nylon n tube tube by bending it.

(i) (i)

S05331

Check Chec k that that ther there e are are no ffue uell leak leaks s afte afterr doin doing g main mainte te-nance anywhere on the fuel system. (1) Co Conn nnect ect a TOYOTA OYOTA han hand– d–hel held d te teste sterr to the the D DLC3 LC3.. (2) Turn the the igni ignitio tion n switc switch h ON and and push push the TOYOT TOYOTA A hand–held tester main switch ON. NOTICE: Do not start the engine. (3) Select Select the the active active test test mode mode on the the TOYOT TOYOTA A hand– hand– held tester. (4) Please Please ref refer er to the the TOYOT TOYOTA A hand– hand–hel held d tester tester ope operrator’s manual for further details. (5) If yo you u have have n no o TOYO TOYOT TA hand–h hand–held eld test tester er,, conne connect ct the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6) (6) Ch Check eck tha thatt there there are no leaks leaks from from any part part of the fuel system. (7) (7) Turn urn the the igni igniti tion on swit switch ch OFF OFF. (8) Disco Disconne nnect ct th the e TOYO TOYOT TA hand hand–h –hel eld d tester tester fro from m the DLC3.

AuthorĂ:

DateĂ:

1438

SF–6 SFI (5S–FE) – FUEL PUMP

FUEL PUMP

SF0D7–03

ON–VEHICLE INSPECTION 1. (a) (b)

S05331

CHECK FU FUEL PU PUMP OP OPERATION Conne Co nnect ct a TOYOT TOYOTA A hand– hand–hel held d te teste sterr to the DL DLC3. C3. Turn Turn the igniti ignition on swi switch tch ON and and push push the TOYOT TOYOTA A hand– hand– held tester main switch ON. NOTICE: Do not start the engine. (c) Select Select the ACTIVE ACTIVE TEST TEST mode mode on the TOYOT TOYOTA A ha hand– nd– held tester. (d) Pleas Please e refer refer to the the TOYO TOYOT TA hand– hand–hel held d tester tester oper operato ator’s r’s manual for further details. (e) If you you have have n no o TOYO TOYOT TA hand–h hand–held eld test tester er,, connec connectt the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See step 7)

(f)

Fuel Inlet Hose S05327

Check Check that that ther there e is is p pres ressur sure e in in the the fuel fuel inlet inlet hose hose from from the fuel filter.

HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the fusible link, fuses, EFI main relay, fuel pump, ECM and wiring connections. (g) (g) Turn urn the the igni igniti tion on swit switch ch OFF OFF. (h) (h) Disco Disconne nnect ct the the TOYO TOYOT TA hand– hand–hel held d teste testerr from from the the DLC3. 2. CHECK FUEL PRESSURE (a) Ch Check eck the batte battery ry posi positiv tive e volta voltage ge is is above above 12 V. V. (b) Disco Disconne nnect ct the the ne negat gative ive (–) termin terminal al cabl cable e from from the the ba batttery.

(c)

Remove the union Remove union bolt bolt and and 2 gasket gaskets, s, and and discon disconnec nectt the the fuel inlet hose from the fuel filter outlet. CAUTION: Put a shop towel under the fuel filter. filter. D Slowly loosen the union bolt. D

S05522

AuthorĂ:

DateĂ:

1439


Fuel Inlet Hose

(d)

SST (Union Bolt) SST (Gauge) Gasket

Gasket Gasket SST (Union)

S05328

Ohmmeter 4

5

Install Install the fue fuell inlet inlet hose hose and and SST SST (pre (pressu ssure re gau gauge) ge) to the the fuel filter outlet with the 3 gaskets and SST (union bolt). SST 092 09268– 68–450 45014 14 (0926 (09268–4 8–41 1190 190,, 904 90405– 05–06 06167 167)) Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) (e) (e) Wipe Wipe off off any any spla splatt tter ered ed gaso gasoliline ne.. (f) Recon Re conne nect ct the nega negativ tive e (–) (–) termi termina nall cable cable to the the bat batter tery y. (g) Co Conne nnect ct a TOYOT TOYOTA A hand– hand–hel held d te teste sterr to the DL DLC3. C3. (See step 1 in check fuel pump operation (a) to (e)) (h) (h) Me Meas asur ure e the the fuel fuel pres pressu sure re.. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm 2, 44 – 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses, fuel hose connections, fuel pump, fuel filter and fuel pressure regulator. (i) (i) Disco Disconne nnect ct the TOYOT TOYOTA A han hand–h d–held eld tester tester from from the DLC3. (j) Start th the engine. (k) (k) Me Meas asur ure e the the fue fuell pre press ssur ure e at idle idle.. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm 2, 44 – 50 psi) (l) Stop the engine. (m) Check Check that the fuel pressure pressure remains remains as speci specified fied for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (n) Aft After er checki checking ng fuel fuel pres pressur sure, e, disco disconn nnect ect the the neg negati ative ve (–) (–) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268–45014 (o) Reconn Reconnect ect the fue fuell inlet inlet hose hose with with 2 new new gask gaskets ets and the union bolt. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) (p) Re Recon conne nect ct the negati negative ve (–) (–) termin terminal al cable cable to the the batte battery ry.. (q) (q) Ch Chec eck k for for fue fuell lea leaks ks.. (See (See page page SF–1 SF–1)) 3. REMOVE RE REAR SE SEAT CU CUSHION 4. REMOV EMOVE E FLO FLOOR OR SER SERVICE ICE HO HOLE COVE OVER 5. DISC DISCON ONNE NECT CT FUE FUEL L PUM PUMP P & SEN SENDE DER R GAU GAUGE GE CONCONNECTOR 6. INSP INSPEC ECT T FU FUEL PUMP RE RESI SIST STA ANCE Using an ohmmeter, ohmmeter, measure the resistance between terminals t erminals 4 and 5. Resistance: 0.2 – 3.0 Ω at 20 C (68 F) If the resistance is not as specified, replace the fuel pump. °

°

S04508

AuthorĂ:

DateĂ:

1440


4

Battery

5

S04509

7. INSP INSPEC ECT T FUE FUEL PU PUM MP OPER PERATION ION Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (–) lead to terminal 5. Check that the fuel pump operates. NOTICE: D These tests must be done quickly (within 10 seconds) to prevent the coil burning out. Keep the fuel pump as far away from the battery as D possible. D Always do the switching at the battery side. If operation is not as specified, replace the fuel pump or lead wire. 8. RECO RE CONN NNEC ECT T FUE FUEL L PUM PUMP P & SEN SENDE DER RG GAU AUGE GE CONCONNECTOR 9. REIN RE INST STAL ALL L FLO FLOOR OR SER SERVICE VICE HOLE HOLE COVE COVER R 10. 10. RE REIN INST STAL ALL L REA REAR R SEA SEAT T CUS CUSHI HION ON

AuthorĂ:

DateĂ:

1441

SF–9 SFI (5S–FE) – FUEL PUMP SF0D8–02

COMPONENTS Type A

Rear Seat Cushion

Floor Service Hole Cover

x8 4 (40, 35 in.·lbf)

Fuel Pump & Sender Gauge Connector No.1 Fuel Tank Protector

Fuel Tank Vent Tube Set Plate

Fuel Hose

Fuel Pump Assembly Fuel Pump Connector Fuel Pump D

Gasket Fuel Pump Filter

D

Clip

Rubber Cushion N·m (kgf·cm, ft·lbf) : Specified torque D Non–reusable part

Z19025

AuthorĂ:

DateĂ:

1442


Type B

Rear Seat Cushion

Floor Service Hole Cover Fuel Pump & Sender Gauge Connector

Fuel Sender Gauge Connector x8 Fuel Sender Gauge

4 (40, 35 in.·lbf)

No.1 Fuel Tank Protector Fuel Pump Flange Fuel Tank Vent Tube Set Plate D

O–Ring

Fuel Filter Ground Plate Fuel Pump Fuel Pump Assembly Fuel Pump Lead Wire D

Housing

Gasket

Fuel Pump Filter D

Clip

Rubber Cushion ”C” Bracket N·m (kgf·cm, ft·lbf) : Specified torque D Non–reusable part

S06038

AuthorĂ:

DateĂ:

1443

SF–11 SFI (5S–FE) – FUEL PUMP SF0D9–03

REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. REMOVE RE REAR SE SEAT CU CUSHION 2. REMOV EMOVE E FLO FLOOR OR SER SERVICE ICE HO HOLE COVE OVER (a) (a) Take ake out out the the flo floor or carp carpet et.. (b) (b) Re Remo move ve the the ser servi vice ce hole hole cove coverr. HINT: At the time of installation, please refer to the following items. Check for fuel leakage. 3. DISC DISCON ONNE NECT CT FUE FUEL L PUM PUMP P & SEN SENDE DER R GAU GAUGE GE CONCONNECTOR 4. REMOV EMOVE EN NO. O.1 1 FU FUEL TAN ANK K PR PROTE OTECTOR CTOR Remove the 2 bolts and No.1 fuel tank protector. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) in.·l bf)

5.

S04583

DISC DISCON ONNE NECT CT FUE FUEL L TUB TUBE E (FU (FUEL EL TUBE TUBE CONN CONNEC EC-TOR) CAUTION: Perform disconnecting and connecting operations of D the fuel tube connector (quick type) after observing the precautions. D As there is retained pressure in the fuel pipe line, prevent it from splashing inside the vehicle compartment. 6. (a)

Vinyl Bag

S04592

REMOVE REMO VE FUE FUEL L PUM PUMP P ASS ASSEM EMBL BLY Y FRO FROM M FUE FUEL L TAN TANK K Remov Re move e the 6 bolt bolts s and and fuel fuel tank tank vent vent tube tube set set plat plate. e. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) in.·l bf) (b) (b) Pu Pullll out out the the fuel fuel pump pump asse assemb mbly ly.. (c) (c) Re Remo move ve the the gas gaske kett from from the the pump pump a ass ssem embl bly y. NOTICE: D Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should D not bent. HINT: At the time of installation, please refer to the following items. Install a new gasket to the pump assembly.

AuthorĂ:

DateĂ:

1444

SF–12 SFI (5S–FE) – FUEL PUMP SF0DA–02

DISASSEMBLY

Type B

1. 2. 3.

DISC ISCONN ONNEC ECT T FUEL FUEL PU PUMP MP CONN ONNEC ECT TOR Type B: DISCONNECT GROUND PLATE Type B: DISCONNECT FUEL SENDER GAUGE CONNECTOR

S06028

4.

Type A

(a) (b) (c) Pull

Type A: REMOVE FUEL PUMP FROM FUEL PUMP BRACKET Pull Pull off off the the lowe lowerr side side of of th the e fuel fuel pump pump from from th the e pump pump bracket. Disconne Disconnect ct the fue fuell hose hose from from the the fuel fuel pum pump, p, and and remove remove the fuel pump. Remov Remove e the the rubber rubber cushio cushion n from from the fue fuell pump pump..

S04603

5.

Type B: REMOVE FUEL SENDER GAUGE. Push down the portion of A with a finger, finger, and push up the sender gauge. NOTICE: Be careful that the arm of the sender gauge should not bent.

Type B

A Push S06033

6.

Type B

S06050

(a) (b) (b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the fuel filter. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) 7.

Type B: REMOVE FUEL PUMP FLANGE Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring of the fuel pump.

Type B

(2)

Type B: REMOVE FUEL FILTER Remov Remove e the the screw screw,, and and pull pull out out the the fuel fuel filt filter er.. Remo Remove ve the the O–r O–rin ing g from from the the fue fuell filt filter er..

(3) (1)

S06030

AuthorĂ:

DateĂ:

1445


8.

Type B

Type B: REMOVE FUEL PUMP LEAD WIRE.

S06027

9.

Type B (3) (1)

(2)

Type B: REMOVE ”C” BRACKET, RUBBER CUSHION AND FUEL PUMP Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration.

S06029

10. REMOVE REMOVE FUEL FUEL PUMP PUMP FILTER FILTER FROM FROM FUEL FUEL PUMP PUMP (a) Using Using a smal smalll scre screwdr wdrive iverr, remov remove e the the clip clip.. (b) (b) Pu Pull ll out out the the pump pump filt filter er.. HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip.

FI6376

AuthorĂ:

DateĂ:

1446

SF–14 SFI (5S–FE)

–

FUEL PUMP SF0DB–01

REASSEMBLY Reassembly is in the reverse order of disassembly. (See page SF–12)

AuthorĂ:

DateĂ:

1447


–

FUEL PUMP SF0DC–01

INSTALLATION Installation is in the reverse order of removal. (See page SF–11)

AuthorĂ:

DateĂ:

1448

SF–16 SFI (5S–FE) – FUEL PRESSURE REGULATOR

FUEL PRESSURE REGULATOR SF0DD–02

COMPONENTS Type A

Rear Seat Cushion


Fuel Pump & Sender Gauge Connector

x8 4 (40, 35 in.·lbf)

No.1 Fuel Tank Protector


Fuel Pump Assembly

D

Gasket

Fuel Pressure Regulator

D

O–Ring

D

O–Ring

Fuel Filter

N·m (kgf·cm, ft·lbf) : Specified torque D Non–reusable part

Z19026

AuthorĂ:

DateĂ:

1449

SF–17 SFI (5S–FE) – FUEL PRESSURE REGULATOR

Type B

Rear Seat Cushion


x8

Fuel Pump and Sender Gauge Connector

4 (40, 35 in.·lbf)



Fuel Pump Assembly

D

Gasket


D

O–Ring

D

O–Ring

Fuel Filter


S06037

AuthorĂ:

DateĂ:

1450

SF–18 SFI (5S–FE) – FUEL PRESSURE REGULAT REGU LATOR OR SF0DE–03

REMOVAL 1.

REMOVE REMO VE FUE FUEL L PUMP PUMP ASS ASSEM EMBL BLY Y FROM FROM FUE FUEL L TAN TANK K (See page SF–11)

2. REMOVE FUEL FILTER (a) Remov Remove e the the screw screw,, and and pull pull out out the the fuel fuel filt filter er.. (b) (b) Remo Remove ve the the O–r O–rin ing g from from the the fue fuell filt filter er.. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the fuel filter. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) S04591

3. (a)

REMOVE REMO VE FUEL FUEL PR PRES ESSU SURE RE RE REGU GULA LAT TOR Remov Remove e the scre screw w, and pull pull out out the the pressu pressure re regu regulat lator or.. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) Remov Remove e the the O–rin O–ring g from from the the pres pressur sure e regul regulato atorr.

(b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the pressure regulator. S04590

AuthorĂ:

DateĂ:

1451


–

FUEL PRESSURE REGUL ATOR ATOR SF0DF–01


AuthorĂ:

DateĂ:

1452

SF–20 SFI (5S–FE) – INJECTOR

INJECTOR SF0DG–03

ON–VEHICLE INSPECTION 1. INSP INSPEC ECT T INJE INJECT CTOR OR OP OPER ERA ATION TION Check operation sound from each injector. (a) With With the eng engine ine runnin running g or cran crankin king, g, use use a soun sound d scope scope to check that there is a normal operating noise in proportion to engine speed.

Sound Scope S05304

(b)

If you you ha have ve no no soun sound d scope scope,, you can check check the the injec injector tor transmission operation with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM.

S05305

2. (a) (a) (b)

INSP INSPEC ECT T INJE INJECT CTOR OR RESI RESIST STAN ANCE CE Disc Discon onne nect ct the the inje inject ctor or con conne nect ctor or.. Using Using an ohm ohmmet meter er,, measu measure re the the resi resistan stance ce betw between een the terminals. Resistance: 13.4 – 14.2 Ω at 20 C (68 F) If the resistance is not as specified, replace the injector. (c) (c) Re Reco conn nnec ectt the the inje inject ctor or conn connec ecto torr.

Ohmmeter

°

°

S05306

AuthorĂ:

DateĂ:

1453

SF–21 SFI (5S–FE) – INJECTOR SF0DH–03

COMPONENTS

High–Tension Cord

44 (450, 33)

Grommet

Cylinder Head Cover

PCV Hose

PCV Hose

Gasket

Injector (Except California) D

Injector (California)

13 (130, 9)

Injector Connector

Delivery Pipe

Insulator Insulator O–Ring

D D

D

O–Ring

D

Grommet Spacer

Engine Wire Clamp

Spacer


S05925

AuthorĂ:

DateĂ:

1454

SF–22 SFI (5S–FE) – INJECTOR SF0DI–03

REMOVAL 1. (a) (b) (b)

REMOVE CY CYLIND INDER HE HEAD CO COVER Disco Disconne nnect ct the 4 high–t high–tens ension ion cords cords from from tthe he clam clamps ps on on the cylinder head cover. Disco Disconne nnect ct tthe he 4 high– high–tens tension ion cords cords ffrom rom the spark spark plugs.

(c) (d) (e)

Disco Disconne nnect ct the PCV hose hose from from the intake intake man manifo ifold. ld. Disco Disconne nnect ct the the PC PCV V ho hose se from from th the e cylin cylinde derr head head cove coverr. Disconn Disconnect ect the the engin engine e wire wire clamp clamp from from the mou mountin nting g bolt bolt of the No.2 timing belt cover. (f) Remov Re move e the the cylind cylinder er head head cover cover.. (See (See pag page e EM– EM–33) 33) NOTICE: Cover the cylinder head with a clean cloth to prevent dirt, etc. getting into the cylinder head.

(c)

(e) (d) S05289

2. (a) (a) (b)

REMOVE REMO VE DE DELI LIVE VER RY P PIP IPE E AND AND INJE INJECT CTOR ORS S Disc Discon onne nect ct the the 4 inje inject ctor or con conne nect ctor ors. s. Remove Rem ove the the 2 bolts bolts ho holdi lding ng the the deliv delivery ery pipe pipe to to the cyl cylin in-der head.

B06353

B06354

(c) Disco Disconne nnect ct the the delive delivery ry pipe pipe from from the the 4 inject injectors ors.. (d) (d) Pu Pull ll out out the the 4 inje inject ctor ors. s. NOTICE: Be careful not to drop the injectors. (e) (e) Rem Remove ove the 4 insulator insulators s (Except (Except Californi California) a) and 2 spacers from the cylinder head. (f) California: Remove the 2 O–rings, insulator and grommet from each injector. (g) Except Califor fornia: Remove the O–ring and grommet from each injector.

AuthorĂ:

DateĂ:

1455

SF–23 SFI (5S–FE) – INJECTOR SF0DJ–03

SST (Hose)

INSPECTION

Union Bolt SST (Union) SST (Clamp)

Fuel Filter (On Vehicle)

SST (Union) Injector

1. INSP INSPEC ECT T INJE INJECT CTOR OR INJ INJEC ECTI TION ON CAUTION: Keep injector clean of sparks during the test.

S05525

(a)

Remove the union Remove union bolt bolt and and 2 gasket gaskets, s, and and discon disconnec nectt the the fuel inlet hose from the fuel filter outlet.

(b)

Connect SST (union Connect (union and hose) hose) to to the the fuel fuel filt filter er outl outlet et with with the 2 gaskets and union bolts. SST SST 0926 09268– 8–41 4104 047 7 (90 (9040 405– 5–09 0901 015) 5) Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)

S05522

Union Bolt SST (Union)

Gasket

SST (Hose)

S05524

SST (Hose) SST (Union) O–Ring SST (Clamp) Vinyl Tube

(c) (d)

Instal Installl the the g grom rommet met and O–rin O–ring g to the inject injector or.. Conne Co nnect ct SST SST (union (union and hose) hose) to the the inje injecto ctorr, and hold hold the injector and union with SST (clamp). SST 092 09268– 68–410 41047 47 (0926 (09268–4 8–41 1100 100,, 092 09268– 68–41 411 110) (e) Put the inject injector or into into the the grad gradua uated ted cylind cylinder er.. CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.

P01078

(f) (f) (g) (h)

S05331

Connec Conn ectt a TOY TOYOT OTA A hand hand–h –hel eld d test tester er to to the the DLC3 DLC3.. Conne Co nnect ct the the ba batte ttery ry negat negative ive (–) cab cable le to the batt battery ery.. Turn Turn the igniti ignition on swi switch tch ON and and push push the TOYOT TOYOTA A hand– hand– held tester main switch ON. NOTICE: Do not start the engine. (i) (i) Sele Se lect ct the the AC ACTI TIVE VE TEST TEST mo mode de on the the TOY TOYOT OTA A hand hand– – held tester. (j) Pleas Please e refer refer to the TOYOT TOYOTA A ha hand nd–he –held ld tester tester opera operator’ tor’s s manual for further details. AuthorĂ:

DateĂ:

1456


(k)

If you you have have n no o TOYO TOYOT TA hand–h hand–held eld test tester er,, connec connectt the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6)

(l) (l)

Connect

Connec Conn ectt SST (wir (wire) e) tto o the the in inje ject ctor or and and bat batte tery ry for for 15 15 se se-conds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842–30070 Volume: 51 – 63 cm3 (3.2 – 3.8 cu in.) per 15 seconds Difference between each injector: 12 cm3 (0.7 cu in.) or less If the injection volume is not as specified, replace the injector.

SST (Wire)

P01077

California

Except California

2. (a)

(b) (b) (c) Z09211

(d) (e) (e)

(f)

INSPECT LEAKAGE In the the condi conditio tion n above above,, discon disconnec nectt the tester tester prob probes es of of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842–30070 Fuel drop: 1 drop or less per 3 minutes Turn urn the the igni igniti tion on swit switch ch OFF OFF. Disco Disconne nnect ct the the ne negat gative ive (–) termin terminal al cabl cable e from from the the ba batttery. Remove the SST. SST SST 0926 09268– 8–41 4104 047, 7, 0984 09842– 2–30 3007 070 0 Disco Disconne nnect ct the the TOYO TOYOT TA hand– hand–hel held d teste testerr from from the the DLC3.

Reconne Recon nect ct the fue fuell inle inlett hose hose to to th the e fu fuel el filter filter out outlet let with with 2 new gaskets and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

S05522

AuthorĂ:

DateĂ:

1457

SF–25 SFI (5S–FE) – INJECTOR SF0Z8–01

INSTALLATION

California New Insulator

1. (a)

New O–Ring

New O–Ring

(b) (b) (c)

New Grommet

(d) (d)

Except California

INST INSTAL ALL L INJ INJEC ECT TORS ORS AND AND DE DELI LIVE VER RY PIP PIPE E California: Install new insulator and grommet to each injector. Exce xcept Califo liforn rnia ia:: Install a new grommet to each injector. California: Apply a light coat of gasoline onto 2 new O–rings, and install them to each injector. Exce xcept Califo liforn rnia ia:: Apply a light coat of gasoline onto a new O–ring, and install it to each injector.

New O–Ring

New Grommet Z09141

(e)

Instal Installl the 2 spac spacers ers and 4 ne new w insul insulato ators rs to the cylind cylinder er head.

(f)

While While turn turnin ing g the the inje injecto ctorr left left and and righ right, t, insta installll itit to the the dedelivery pipe. Install the 4 injectors. Posi Po siti tion on the the inj injec ecto torr conne connect ctor or upw upwar ard. d.

Spacer New Insulator

Spacer

S05980

Upward

(g) (g) Connector Turn Push S05978

AuthorĂ:

DateĂ:

1458


(h) (i)

Attach the Attach the 4 injec injector tors s and and deliv delivery ery pipe pipe assem assembly bly to the the cylinder head. Temp empora oraril rily y instal installl the the 2 bol bolts ts hol holdi ding ng tthe he d del elive ivery ry pipe pipe to the cylinder head.

B06352

(j) (j) Chec Ch eck k ttha hatt the the inje inject ctor ors s rot rotat ate e smo smoot othl hly y. HINT: If injectors do not rotate smoothly, smoothly, the probable cause is incorrect installation of O–rings. Replace the O–rings. (k) (k) Po Posi siti tion on the the inj injec ecto torr conn connec ecto torr upwa upward rd.. (l) Tighte Tighten n the 2 bolt bolts s hol holdi ding ng the deliv delivery ery pipe pipe to the the cylin cylinde derr head. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

Upward Connector

Turn

S05976

No.1

(m) Co Conne nnect ct the 4 inj inject ector or conne connecto ctors. rs. HINT: The No.1 and No.3 injector connectors are brown, and the No.2 and No.4 injector connectors are gray.

Gray

No.2 No.3 Brown

No.4 B06351

2. (a) (b) (c) (d)

(b)

(d)

(e) (f)

(c) S05289

3.

INST INSTA ALL CYLIN YLIND DER HEA EAD D COVE OVER Instal Installl the the cylin cylinde derr head head cove coverr. (See (See page page EM–5 EM–53) 3) Conne Co nnect ct the PC PCV V hose hose to the intake intake man manifo ifold. ld. Conne Co nnect ct the the PCV hose hose to the cylind cylinder er hea head d cover cover.. Instal Installl the the engi engine ne wire wire clamp clamp to to the the moun mountin ting g bolt bolt o off the No.2 timing belt cover. Conne Co nnect ct the the 4 high high–te –tensi nsion on cord cords s to the the spar spark k plugs plugs.. Install Install the the 4 high– high–ten tensio sion nc cor ords ds to the clamp clamps so on n the the cylincylinder head cover. CHEC CH ECK K FOR FOR FUEL FUEL LEAK LEAKS S (Se (See e page page SF–1 SF–1))

AuthorĂ:

DateĂ:

1459

SF–27 SFI (5S–FE) – FUEL TANK AND LINE

FUEL TANK AND LINE SF0DL–03

COMPONENTS CAUTION: Always use new gaskets when replacing the fuel tank or component parts. Apply the proper torque to all parts tightened Location of Fuel Tank Cushion x8

No.1 Fuel Tank Tank Protector

Heated Oxygen Sensor (Bank 1 Sensor 2) HINT: D Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns. D

Fuel Tank Vent Tube Set Plate Fuel Pump

After installing the heated oxygen sensor, check that the sensor wire is not twisted, if it is twisted, remove the heated oxygen sensor and reinstall it.

Charcoal Canister

Fuel Inlet Pipe Shield

Fuel Tank Cap

Vent Line Hose Fuel Outlet Tube

Gasket EVAP Line Hose

Gasket

Fuel Inlet Pipe Fuel Inlet Hose

Fuel Tank Fuel Inlet Pipe Protector 39 (400, 29)

Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) Fuel Tank Band

Heat Insulator

44 (450, 33) 56 (570, 41)

Gasket

Center Exhaust Pipe

56 (570, 41)

N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part

B06469

AuthorĂ:

DateĂ:

1460

SF–28 SFI (5S–FE) – FUEL TANK AND LINE SF0DM–03

INSPECTION Crack

Leakage

Deformation BO0919

SST

Use SST 28 N·m (285 kgf·cm, 21ft·lbf)

SST: 09631–22020

INSPECT FUEL TANK AND LINE (a) Check Check the fue fuell line lines s for for crack cracks s or leakag leakage, e, and and all all conn connecections for deformation. (b) Check Check the fue fuell tank tank vap vapor or ven ventt syste system m hose hoses s and and conn connecections for looseness, sharp bends or damage. (c) Ch Check eck the the ffue uell tank tank for for defor deformat mation ion,, cracks cracks,, fuel fuel leaka leakage ge or tank band looseness. (d) Ch Check eck the filler filler neck neck for for damag damage e or fue fuell leaka leakage. ge. (e) Ho Hose se and and pipe pipe connec connectio tions ns are are as as show shown n in the the illu illustr straation. If a problem is found, repair or replace the parts as necessary.

Fulcrum Length 30 cm (11.81 in.) Z10162

2 – 7 mm (0.08 – 0.28 in.) Hose

Pipe

Clip 0 – 3 mm (0 – 0.12 in.)

FU0041

AuthorĂ:

DateĂ:

1461

SF–29 SFI (5S–FE) – THROTTLE BODY

THROTTLE BODY

SF0DN–03

ON–VEHICLE INSPECTION Move

1. (a)

INSPECT TH THROTTLE BODY Check Ch eck tha thatt the the th throt rottle tle linkag linkage em move oves s smoot smoothly hly..

(b) (b)

Chec Ch eck k the the vac vacuu uum m at at eac each h por port. t. Start the engine. D Check the vacuum with your finger. D

B01277

P R E

Port name

At idle

Other than idle

Mark E

Vacuum

Vacuum

Mark P

No vacuum

Vacuum

Mark R

No vacuum

No vacuum

B00525

2. (a) (a) (b) (c) (c)

INSP INSPEC ECT T THR THROTTL OTTLE E POS POSIT ITIO ION NS SEN ENSO SOR R Disc Discon onne nect ct the the sens sensor or conn connec ecto torr. Disco Disconne nnect ct the the va vacuu cuum m ho hose se from from th the e thrott throttle le open opener er.. Appl Ap ply y vac vacuu uum m to to the the thro throttl ttle e ope opene nerr.

(d)

Using Using an an ohmm ohmmete eterr, measu measure re the the resi resista stance nce bet betwe ween en each terminal.

Disconnect

Vacuum B01278

VTA E2 VC

Ohmmeter

Clearance between

Between

lever and stop screw

terminals

0 mm (0 in.)

VTA – E2

0.2 – 5.7 kΩ

VTA – E2

2.0 – 10.2 kΩ

VC – E2 E2

2.5 – 5.9 5.9 kΩ

Throttle valve fully open – B01282

(e) (f) (f) 3. (a)

Resistance

Reconne Recon nect ct the vacuum vacuum hose hose to the thrott throttle le open opener er.. Reco Re conn nnec ectt the the sens sensor or conn connec ecto torr. INSPECT THROTTLE OPENER Allow Allow the engin engine e to warm warm up to to norma normall op oper erati ating ng tem tempe perarature.

AuthorĂ:

DateĂ:

1462

SF–30 SFI (5S–FE) – THROTTLE BODY

(b)

(c) (c) S05331

(d)

Plug

Disconnect

Connectt a TOYOT Connec TOYOTA A hand hand–he –held ld teste testerr or or OBDII OBDII scan scan tool tool.. (1) Re Remov move e the fuse fuse cover cover on the instru instrumen mentt pane panel. l. (2) Co Conne nnect ct a TOYOT TOYOTA A hand hand–he –held ld tester tester or OBDII OBDII scan tool to the DLC3. (3) Please Please refer refer to the TOYOT TOYOTA A ha hand– nd–he held ld teste testerr or OBDII scan tool operator’s manual for further details. Check eck the the idle spe pee ed. Idle speed: 700 ± 50 rpm Check and adjust Check adjust the thrott throttle le ope opener ner settin setting g speed speed.. (1) Disconne Disconnect ct the vacuu vacuum m hos hose e from from the thrott throttle le ope openner, and plug the hose end. (2) (2) Ma Main inta tain in the the eng engin ine e sp spee eed d at 2,5 2,500 00 rpm rpm.. (3) (3) Re Rele leas ase e the the thro thrott ttle le valv valve. e. (4) (4) Ch Chec eck k that that the the thro thrott ttle le ope opene nerr is set. set. Throttle opener setting speed: 1,300 – 1,500 rpm (w/ Cooling fan OFF)

B01279

(5)

2.5 mm Hexagon Wrench

(e)

Using Using a 2.5 mm hexago hexagon n wren wrench, ch, loosen loosen the lock lock nut and adjust the throttle opener setting speed by turning the throttle opener adjusting screw. Tighten the lock nut. (6) Re Recon connec nectt the vacuu vacuum m hose hose to to th the e th throt rottle tle opene openerr. Disconne Disconnect ct th the e TOYOT TOYOTA Ah hand and–he –held ld tester tester or OBDII OBDII s scan can tool.

B01280

AuthorĂ:

DateĂ:

1463

SF–31 SFI (5S–FE) – THROTTLE BODY SF0DO–03

COMPONENTS Vacuum Hose 19 (195, 14) D

Gasket

Accelerator Cable

Throttle Cable Cable (A/T) Throttle Position Sensor Connector Throttle Body IAC Valve Connector

Water Bypass Hose Air Hose (California)

EVAP Hose EVAP Hose

Air Cleaner Hose

EVAP Hose

PCV Hose

IAT Sensor Connector

Air Cleaner Cap

VSV Connector for EVAP


B00526

AuthorĂ:

DateĂ:

1464

SF–32 SFI (5S–FE) – THROTTLE BODY SF0DP–03

REMOVAL 1. 2. 3.

5. (a) (b) (b) (c)

DRAIN ENGINE COOLANT REMO RE MOVE VE AIR AIR CLE CLEAN ANER ER CA CAP P (Se (See e pag page eE EM– M–69 69)) D IS IS CO CO N NN N EC EC T A CC CC EL EL ER ER AT AT O R C AB AB LE LE FR FR O OM M THROTTLE BODY A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY REMOVE THROTTLE BODY Disco Disconne nnect ct the the throt throttle tle posi positio tion n senso sensorr conne connecto ctorr. Disc Discon onne nect ct the the IAC IAC val valve ve con conne nect ctor or.. Disco Disconne nnect ct the the 2 vacu vacuum um hose hoses s from from the the thro throttl ttle e body body..

(d) (e) (f)

Remove th the 3 bolts. Disco Disconne nnect ct the the th throt rottle tle body body from from the intake intake man manifo ifold. ld. Remove the gasket.

(g)

Disco Disconne nnect ct th the e air hose hose for for air air assist assist syst system em (Ca (Calif liforn ornia) ia) and the 2 water bypass hoses from the throttle body, and remove the throttle body.

4.

B01283

Water Bypass Hose

Air Hose

Water Bypass Hose S05534

AuthorĂ:

DateĂ:

1465

SF–33 SFI (5S–FE) – THROTTLE BODY SF0DQ–03

INSPECTION 1. (a)

B00527

Throttle Lever

Stop Screw

2. (a) (b) (b) (c)

No Clearance

(d)

Disconnect Vacuum

CLEAN TH THROTTLE BO BODY Using Using a soft soft brus brush h and carb carbure uretor tor clea cleane nerr, clean clean the the cast cast parts. (b) Using Using compr compress essed ed air air,, clean clean all all the pass passage ages s and aper aper-tures. NOTICE: To prevent deterioration, do not clean the throttle position sensor and throttle opener.

B01284

3.

INSPECT TH THROTTLE BO BODY Disco Disconne nnect ct the thrott throttle le open opener er vacu vacuum um h hose ose from from the the throttle body. Appl Ap ply y vacu vacuum um to to the the thro throttl ttle e open opener er.. Check Check that that there there is no no clea clearan rance ce betw betwee een n the the throt throttle tle stop stop screw and throttle lever when the throttle valve is fully closed. Reconnec Reconnectt the throt throttle tle ope opene nerr vacuu vacuum m ho hose se to to the the throt throttle tle body. INSP INSPEC ECT T THR THROTTL OTTLE E POS POSIT ITIO ION NS SEN ENSO SOR R (See page SF–29)

AuthorĂ:

DateĂ:

1466

SF–34 SFI (5S–FE) – THROTTLE BODY SF0DR–03

INSTALLATION 1. (a) (a)

(b) (b) (c)

(c) (b) S05534

(d) (e) (f) (f) (g) (g) 2. 3. B01283

4. 5.

INSTALL TH THROTTLE BO BODY Conne Co nnect ct the the water water bypass bypass hose hose (from (from the wat water er bypa bypass ss pipe) to the throttle body. Conn Co nnec ectt the water water byp bypas ass s hose hose (fro (from m the wa water ter outl outlet et)) to the throttle body. California: Connect the air hose (from the intake manifold) for air assist system to the throttle body. Install Install a new gasket gasket and the throttl throttle e body body with with the the 3 bolts. bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Conne Co nnect ct the the 2 vacuu vacuum m hose hoses s to the thrott throttle le bod body y. Conn Co nnec ectt the tthr hrot ottl tle e posi positi tion on sens sensor or conn connec ecto torr. Conn Co nnec ectt the the IAC IAC val valve ve conn connec ecto torr. CONN CONNEC ECT T ACCE ACCELE LERA RAT TOR CAB CABLE LE TO TO THRO THROTT TTLE LE BODY A/T: CONNECT THROTTLE CABLE TO THROTTLE BODY INST INSTAL ALL L AIR AIR CLE CLEAN ANER ER CA CAP P (See (See page page EM– EM–75 75)) FILL WITH ENGINE COOLANT

AuthorĂ:

DateĂ:

1467

SF–35 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE

IDLE AIR CONTROL (IAC) VALVE

SF0DS–03

ON–VEHICLE INSPECTION 1. (a) (a)

TE1

INSP INSPEC ECT T IA IAC VAL VALVE VE OPE OPERA RATI TION ON Init Initiial cond condiition tions: s: D Engine at normal operating temperature D Idle speed set correctly D Transmission in neutral position

(b)

Using Using SST SST,, co conne nnect ct termi terminal nals s TE1 and E1 o off the the DL DLC1. C1. SST 09843–18020 (c) After the the eng engin ine e spe speed ed is is kept kept at at 900 900 – 1,30 1,300 0 rpm rpm for for 5 seseconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) (d) Re Remo move ve the the S SST ST from from the the DLC DLC1. 1. SST 09843–18020

E1

SST

A07370

Ohmmeter

2. INSP INSPEC ECT T IAC IAC VALVE ALVE RE RESI SIST STAN ANCE CE NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from –10 C (14 F) to 50 C (122 F) and ”Hot” is from 50 C (122 F) to 100 C (212 F). (a) (a) Disc Discon onne nect ct the the IAC IAC val valve ve conn connec ecto torr. (b) Using Using an ohm ohmmet meter er,, measu measure re the the resi resista stance nce bet betwee ween n terterminal +B and other terminals (ISCC, ISCO). Resistance: °

+B

°

ISCC

°

°

°

°

°

°

ISCO

B01281

Cold

17.0 – 24.5 Ω

Hot

21.5 – 28.5 Ω

If the resistance is not as specified, replace the IAC valve. (c) (c) Re Reco conn nnec ectt th the e IAC IAC val valve ve conn connec ecto torr.

AuthorĂ:

DateĂ:

1468

SF–36 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE SF0DT–03

COMPONENTS Vacuum Hose D

Gasket

Accelerator Cable

Throttle Cable Cable (A/T)

Throttle Position Sensor Connector Throttle Body Water Bypass Hose Air Hose (California)

IAC Valve Connector 19 (195, 14)

EVAP Hose EVAP Hose Air Cleaner Hose EVAP Hose

Throttle Body PCV Hose

IAT Sensor Connector D

Gasket

IAC Valve Air Cleaner Cap VSV Connector for EVAP


B01285

AuthorĂ:

DateĂ:

1469

SF–37 SFI (5S–FE) – IDLE AIR CONTROL (IAC) ( IAC) VALVE SF0DU–03

REMOVAL 1.

Except California

REMO RE MOVE VE THRO THROTT TTLE LE BODY BODY (See (See page page SF–3 SF–32) 2)

2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket.

B01276

AuthorĂ:

DateĂ:

1470

SF–38 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE SF0DV–03

INSPECTION INSPECT IAC VALVE OPERATION (a) Con Conne nect ct the posi positiv tive e (+) lead lead from from the bat batter tery y to termi terminal nal +B and negative (–) lead to terminal ISCC, and check that the valve is closed.

Battery

ISCC Closed +B S01477

(b)

Connect Conne ct the posi positiv tive e (+) lead lead from from the bat batter tery y to termi terminal nal +B and negative (–) lead to terminal ISCO, and check that the valve is open. If operation is not as specified, replace the IAC valve.

Battery Open +B

ISCO

S01478

AuthorĂ:

DateĂ:

1471

SF–39 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE SF0DW–03

INSTALLATION 1. (a) (a) (b) (b) 2.

INSTALL IA IAC VALVE Plac Place e a new new gas gaske kett on the the thr throt ottl tle e body body.. Inst Instal alll th the e IA IAC C va valv lve e wit with h the the 4 scr screw ews. s. INST INSTAL ALL L THRO THROTT TTLE LE BODY BODY (See (See page page SF–3 SF–34) 4)

New Gasket B01275

AuthorĂ:

DateĂ:

1472

SF–40 SFI (5S–FE) – EFI MAIN RELAY

EFI MAIN M AIN RELA RE LAY Y

SF0DX–03

INSPECTION EFI Main Relay

1. 2.

REMOVE RELAY BOX COVER REMO RE MOVE VE EFI EFI MAI MAIN N REL RELA AY (Ma (Mark rkin ing: g: EFI) EFI)

S05392

Continuity Ohmmeter

Ohmmeter

2

1

5

3 No Continuity

3. (a) (a)

INSPECT EFI MAIN RELAY Insp Inspec ectt the the rela relay y cont contin inui uity ty.. (1) Using Using an ohm ohmmet meter er,, check check tha thatt there there is is conti continui nuity ty between terminals 1 and 2. If there is no continuity, replace the relay. (2) (2) Ch Chec eck k that that there there is is no con contin tinui uity ty be betwe tween en term termin inal als s 3 and 5. If there is continuity, replace the relay.

S04970

(b) (b) 2

Ohmmeter

1 5

3 Battery Continuity

Insp Inspec ectt the the rela relay y ope opera rati tion on.. (1) Apply Apply batte battery ry posi positiv tive e volta voltage ge acro across ss term termina inals ls 1 and 2. (2) Using Using an ohm ohmmet meter er,, check check tha thatt there there is is conti continui nuity ty between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL EF EFI MA MAIN RELAY 5. REIN EINSTALL RELAY LAY BOX COVER OVER

S04969

AuthorĂ:

DateĂ:

1473

SF–41 SFI (5S–FE) – CIRCUIT OPENING RELAY

Circuit Opening Relay

CIRCUIT OPENING RELAY

SF0DY–03

INSPECTION 1. 2.

REMOVE RELAY BOX COVER REMO RE MOVE VE CIRC CIRCUI UIT T OPE OPENI NING NG RE RELA LAY Y (Ma (Mark rking ing:: CIR CIR OPN)

S05389

Continuity Ohmmeter

Ohmmeter

2

1

5

3 No Continuity

3. (a) (a)

INSP INSPEC ECT T CIR CIRCUIT OPE OPENIN NING R REL ELA AY Insp Inspec ectt the the rela relay y cont contin inui uity ty.. (1) Using Using an ohm ohmmet meter er,, check check tha thatt there there is is conti continui nuity ty between terminals 1 and 2. If there is no continuity, replace the relay. (2) (2) Ch Chec eck k that that there there is is no con contin tinui uity ty be betwe tween en term termin inal als s 3 and 5. If there is continuity, replace the relay.

S04970

(b) (b) 2

Ohmmeter

1 5

3 Battery Continuity

Insp Inspec ectt the the rela relay y ope opera rati tion on.. (1) Apply Apply batte battery ry posi positiv tive e volta voltage ge acro across ss term termina inals ls 1 and 2. (2) Using Using an ohm ohmmet meter er,, check check tha thatt there there is is conti continui nuity ty between terminals 3 and 5. If there is no continuity, replace the relay. 4. REIN RE INST STAL ALL LC CIR IRCU CUIT IT OPEN OPENIN ING GR REL ELA AY 5. REIN EINSTALL RELAY LAY BOX COVER OVER

S04969

AuthorĂ:

DateĂ:

1474

SF–42 RECIRCULATION (EGR) SFI (5S–FE) – VSV FOR EXHAUST GAS RECIRCULATION

VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF0DZ–03

COMPONENTS

VSV Connector for EGR

Vacuum Hose

VSV for EGR

B06348

AuthorĂ:

DateĂ:

1475

SF–43 SFI (5S–FE) – VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF0E0–03

INSPECTION 1.

Ohmmeter

REMOVE VSV

2. (a) (a)

INSPECT VSV Insp Inspec ectt the the VSV VSV for for open open circ circui uit. t. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39 Ω at 20 C (68 F) If there is no continuity, replace the VSV.

Continuity

°

°

S05259

Ohmmeter

(b) (b)

Insp Inspec ectt the the VSV VSV for for grou ground nd.. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV.

No Continuity

S05260

(c) (c)

Air

Insp Inspec ectt the the VSV VSV oper operat atio ion. n. (1) (1) Ch Chec eck k th that at air air flow flows s from from port ports s E to to G G..

E G

S05261

(2) (2) Apply Apply batter battery y posit positive ive volt voltag age e acros across s the term termin inals als.. (3) Ch Check eck tha thatt air air flows flows from from port port E tto o filt filter er.. If operation is not as specified, replace the VSV. 3. REINSTALL VSV

Air

Battery

E Filter

S05262

AuthorĂ:

DateĂ:

1476

SF–44 EVAPORATIVE EMISSION (EVAP) SFI (5S–FE) – VSV FOR EVAPORATIVE

VSV FOR EVAPORATIVE EMISSION (EVAP) SF0E1–03

COMPONENTS

VSV for EVAP VSV Connector for EVAP

EVAP Hose

S05276

AuthorĂ:

DateĂ:

1477

SF–45 SFI (5S–FE) – VSV FOR EVAPORATIVE EMISSION (EVAP) SF0E2–03

INSPECTION 1.

REMOVE VSV

2. (a) (a)


Ohmmeter Continuity

°

°

S05263

(b) (b)


Ohmmeter No Continuity

S05264

(c) (c)

Insp Inspec ectt the the VSV VSV oper operat atio ion. n. (1) Ch Check eck tha thatt ai airr dose dose not not fflow low from from po ports rts E to F. NOTICE: Never apply more than 93 kPa (0.95 kgf/cm 2, 13.5 psi) of pressure compressed air to the VSV.

Air

E

F

S05265

(2) (2) Apply Apply batter battery y posit positive ive volt voltag age e acros across s the term termin inals als.. (3) (3) Ch Chec eck k that that air air flo flows ws fro from m po port rts s E to to F. F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV

Air

E

F

Battery

S05266

AuthorĂ:

DateĂ:

1478

SF–46 SFI (5S–FE) – VSV FOR VAPOR PRESSURE SENSOR

VSV FOR VAPOR PRESSURE SENSOR SF0E3–03

COMPONENTS

VSV for Vapor Pressure Sensor Connector

VSV for Vapor Pressure Sensor

Vacuum Hose

Charcoal Canister

B06550

AuthorĂ:

DateĂ:

1479

SF–47 SFI (5S–FE) – VSV FOR VAPOR PRESSURE SENSOR SF0E4–04

INSPECTION 1.

REMOVE VSV

2. (a) (a)


Ohmmeter Continuity

°

°

B01273

(b) (b)



B00798

(c) (c)

Air

Insp Inspec ectt the the VSV VSV oper operat atio ion. n. (1) (1) Ch Chec eck k th that at air air flow flows s from from port ports s E to to G G..

E G

B00799

(2) (2) Apply Apply batter battery y posit positive ive volt voltag age e acros across s the term termin inals als.. (3) (3) Ch Chec eck k that that air air flo flows ws fro from m po port rts s E to to F. F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV

Air

E

F

Battery

B00800

AuthorĂ:

DateĂ:

1480

SF–48 SFI (5S–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR

ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF0E5–03

COMPONENTS

ECT Sensor Connector ECT Sensor

D

D

Gasket

Non–reusable part

B06361

AuthorĂ:

DateĂ:

1481

SF–49 SFI (5S–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF0E6–03

INSPECTION 1. 2.

3. 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. 4. REINSTALL ECT SENSOR 5. REFILL ILL WI WITH EN ENGINE CO COOLANT

Ohmmeter

30 20 10 Ω

k e c n a t s i s e R

5 3 2

DRAIN ENGINE COOLANT REMOVE EC ECT SE SENSOR

Acceptable

1 0.5 0.3 0.2 0.1 –20

0

20 40 60 80 100

(–4) (32) (68) (104) (140) (176) (212) S01196 S01699

Temperature °C (°F)

Z17274

AuthorĂ:

DateĂ:

1482

SF–50 SFI (5S–FE) – INTAKE AIR TEMPERATURE (IAT) SENSOR

INTAKE INTAKE AIR AI R TEMPERA TEMP ERATURE TURE (IA ( IAT) T) SENSOR S ENSOR SF0E7–03

COMPONENTS Grommet

IAT Sensor

IAT Sensor Connector S05277

AuthorĂ:

DateĂ:

1483

SF–51 SFI (5S–FE) – INTAKE AIR TEMPERATURE TEMPERATURE (IAT) ( IAT) SENSOR SF0E8–03

INSPECTION 1.

2. INSPECT IAT SE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the sensor. 3. REINSTALL IA IAT SE SENSOR

Ohmmeter

Ω


REMOVE IAT SENSOR

30 20 10 5 3 2

Acceptable

1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100

(–4)(32)(68)(104)(140)(176)(212)

Temperature C ( F) °

°

Z17273

AuthorĂ:

DateĂ:

1484

SF–52 SFI (5S–FE) – MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SF0E9–03

COMPONENTS

MAP Sensor and Bracket Assembly

MAP Sensor

Vacuum Hose

MAP Sensor Connector

Wire Clamp

B00528

AuthorĂ:

DateĂ:

1485

SF–53 SFI (5S–FE) – MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SF0EA–03

Ohmmeter

INSPECTION 1. (a) (a) (b) (b) (c)

Disconnect

E2

VC

S05545

2. (a) (a) (b) (c)

Disconnect

(d)

Vacuum w/o Immobilizer ECM

(d) (d) (e) (e)

PIM

(e)

INSP INSPEC ECT T POW POWER ER SOUR SOURCE CE VOL VOLTAGE AGE OF MA MAP P SENSENSOR Disc Discon onne nect ct the the MA MAP P sens sensor or con conne nect ctor or.. Turn urn the the igni igniti tion on swit switch ch ON. ON. Using Using a voltmet voltmeter er,, meas measure ure the voltag voltage e betw between een connec connec-tor terminals VC and E2 of the wiring harness side. Voltage: 4.5 – 5.5 V Turn urn the the igni igniti tion on swit switch ch OFF OFF. Reco Re conn nnec ectt the the MAP MAP sens sensor or con conne nect ctor or..

INSP INSPEC ECT T POWE POWER R OUTP OUTPUT UT OF MA MAP P SENS SENSOR OR Turn urn the the igni igniti tion on swit switch ch ON. ON. Disco Disconne nnect ct the the vacuu vacuum m hose hose from from the MAP sensor sensor.. Connect Conn ect a volt voltmet meter er to term termina inals ls PIM PIM and and E2 of of the the E ECM, CM, and measure the output voltage under ambient atmospheric pressure. Apply Apply vacuu vacuum m to the the MA MAP P sens sensor or in in 13.3 13.3 kPa kPa (10 (100 0 mm mmHg Hg,, 3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.69 in.Hg). Measur Mea sure e the volta voltage ge drop drop from from step step (c) abo above ve for for each each segment. Voltage Drop:

Voltmeter

Applied Vacuum kPa mmHg in.Hg

E2

Voltage drop V

13.3

26.7

40.0

53.5

66.7

100 3.94

200 7.87

300 11.81

400 15.75

500 19.69

0.3 – 0.5 0.7 0.7 – 0.9 0.9 1.1 1.1 – 1.3 1.3 1.5 1.5 – 1.7 1.7 1.9 1.9 – 2.1 2.1

w/ Immobiliser ECM

A03009

PIM (+)

(f) (f) (g)

E2 (–)

Turn urn the the igni igniti tion on swit switch ch OFF OFF. Recon Re conne nect ct the the vacuum vacuum hose hose to to the the MAP sensor sensor..

B01912

AuthorĂ:

DateĂ:

1486

SF–54 SFI (5S–FE) – VAPOR PRESSURE SENSOR

VAPOR PRESSURE SENSOR SF0EF–04

COMPONENTS

Vapor Pressure Sensor (Type B) Vapor Pressure Sensor (Type A)

Vapor Pressure Sensor Connector

Vacuum hose

Charcoal Canister

B06554

AuthorĂ:

DateĂ:

1487

SF–55 SFI (5S–FE) – VAPOR PRESSURE SENSOR SF0EG–03

INSPECTION Voltmeter

1. (a) (b) (b) (c)

Disconnect VC E2 B06551

(d) (d) (e)

2.

Type A

(a) (a) (b) Pressure Vacuum

(c) Disconnect

Type B Disconnect Pressure

P

Vacuum

w/o Immobiliser ECM

PTNK E2

(d) (d) (e)

Voltmeter

w/ Immobiliser PTNK (+) ECM

B06552 B06553 S05603 A03018

INSPE INSPECT CT POWE POWER R SOUR SOURCE CE VOL VOLTAGE AGE OF OF VAP APOR OR PRESSURE SENSOR Disco Disconne nnect ct the the vapor vapor pressu pressure re sens sensor or conn connect ector or.. Turn urn the the igni igniti tion on swit switch ch ON. ON. Using Using a voltmet voltmeter er,, meas measure ure the voltag voltage e betw between een connec connec-tor terminals VC and E2 of the wiring harness side. Voltage: 4.5 – 5.5 V Turn urn the the igni igniti tion on swit switch ch OFF OFF. Recon Re conne nect ct the the vapor vapor pressu pressure re sens sensor or conn connect ector or..

INSP INSPEC ECT T POWE POWER R OUT OUTPU PUT T OF OF VAP VAPOR OR PRE PRESS SSUR URE E SENSOR Turn urn the the ign ignit itio ion n swi switc tch h ON. ON. Disco Disconne nnect ct the vacuum vacuum hose hose from from the vapor vapor pres pressur sure e sensor. Conne Co nnect ct a volt voltmet meter er to termin terminal als s PTNK PTNK and E2 of the ECM, and measure the output voltage under the following conditions: (1) Apply Apply vacu vacuum um (2.0 (2.0 kPa kPa (15 mmH mmHg, g, 0.5 0.59 9 in.H in.Hg)) g)) to the vapor pressure sensor. Voltage: 1.3 – 2.1 V (2) Re Relea lease se the the vacu vacuum um from from the the vapor vapor pressu pressure re sensensor. Voltage: 3.0 – 3.6 V (3) Apply Apply pre press ssur ure e (1. (1.5 5 kPa kPa (15 (15 g gf/ f/cm cm2, 0.22 psi)) to the vapor pressure sensor. Voltage: 4.2 – 4.8 V Turn urn the the igni igniti tion on swit switch ch OFF OFF. Recon Re conne nect ct the the vacuu vacuum m hose hose to to the the vapor vapor pressu pressure re sensensor.

E 2 (– )

B06570

AuthorĂ:

DateĂ:

1488

SF–56 SFI (5S–FE) – KNOCK SENSOR

KNOCK SENSOR SF0ED–03

COMPONENTS

Knock sensor 1

Knock Sensor 1 Connector

B06349

AuthorĂ:

DateĂ:

1489

SF–57 SFI (5S–FE) – KNOCK SENSOR SF0EE–03

INSPECTION 1. (a) (b) (b)

SST

Ohmmeter

REMOVE KNOCK SENSOR 1 Disco Disconne nnect ct the knock knock sensor sensor conne connecto ctorr. Usin Using g SST SST, remo remove ve the the kno knock ck sen senso sorr. SST 09816–30010

B06350

No Continuity

P01630

2. INSPECT K KN NOCK SE SENSOR 1 Using an ohmmeter, ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 3. REINSTALL KN KNOCK SENSOR 1 (a) Using Using SST, SST, inst instal alll the the knock knock sensor sensor.. SST 09816–30010 Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (b) (b) Co Conn nnec ectt the the knoc knock k sens sensor or con conne nect ctor or..

AuthorĂ:

DateĂ:

1490

SF–58 SFI (5S–FE) – AIR–FUEL RATIO (A/F) SENSOR (California)

AIR–FUEL RATIO RATIO (A/F) SENSOR (California) SF0EB–03

COMPONENTS

No.3 Exhaust Manifold Heat Insulator A/F Sensor Connector

Clamp

A/F Sensor 44 (450, 32)

N·m (kgf·cm, ft·lbf) : Specified torque

B06358

AuthorĂ:

DateĂ:

1491

SF–59 SFI (5S–FE) – AIR–FUEL RATIO (A/F) SENSOR (California) SF0EC–04

INSPECTION

+B

Ohmmeter HT

1. (a) (a) (b)

INSP INSPEC ECT T HEA HEATE TER R RES RESIS IST TAN ANCE CE OF A/F A/F SENS SENSOR OR Disc Discon onne nect ct the the A/F A/F sen senso sorr conn connec ecto torr. Using Using an ohmm ohmmete eterr, measu measure re the the resi resista stance nce bet betwee ween n terterminals +B and HT. Resistance: 0.8 – 1.4 Ω at 20 C (68 F) If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) (c) Reco Reconn nnec ectt the the A/F A/F sen senso sorr con conne nect ctor or.. 2. INSP INSPEC ECT T OPE OPERATION TION OF A/F A/F SEN SENSO SOR R (See page DI–152 DI–152)) °

B06365

AuthorĂ:

DateĂ:

°

1492

SF–60

SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 1/Except Calif.)

HEATED OXYGEN SENSOR (Bank 1 Sensor 1/Except Calif.) SF0EH–03

COMPONENTS

Heated Oxygen Sensor (Bank 1 Sensor 1) Connector

Clamp

Heated Oxygen Sensor (Bank 1 Sensor 1) 44 (450, 32)

N·m (kgf· (kgf·cm, cm, ft·l ft·lbf) bf) : Specif Specified ied torq torque ue

B06359

AuthorĂ:

DateĂ:

1493

SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 1/Except Calif.)

SF–61 SF0EI–03

INSPECTION

+B

1.

Ohmmeter HT

INSP INSPEC ECT T HEA HEATE TER R RES RESIS IST TAN ANCE CE OF HE HEA ATED TED OXY OXY-GEN SENSOR (a) Disco Disconne nnect ct the oxygen oxygen sensor sensor connec connector tor.. (b) Using Using an ohmm ohmmete eterr, measu measure re the the resi resista stance nce bet betwee ween n terterminals +B and HT. Resistance: 11 – 16 Ω at 20 C (68 F) If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) (c) Re Reco conn nnec ectt the the oxyg oxygen en sen senso sorr conn connec ecto torr. 2. INSP INSPEC ECT T OPE OPERA RATI TION ON OF HE HEA ATED TED OXY OXYGE GEN N SENSENSOR (See page DI–66 DI–66)) °

B06363

AuthorĂ:

°

DateĂ:

1494

SF–62 SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 2)

HEATED OXYGEN SENSOR (Bank 1 Sensor 2) SF0EJ–03

COMPONENTS

Passenger’s Seat

37 (375, 27)

Connector for Seat Heated Oxygen Sensor (Bank 1 Sensor 2) 44 (450, 32)

Clamp Heated Oxygen Sensor Connector (Bank 1 Sensor 2)

Grommet

N·m (kgf·cm, ft·lbf) : Specified torque

Z19284

AuthorĂ:

DateĂ:

1495

SF–63 SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 2) SF0EK–03

Ohmmeter

INSPECTION 1.

+B

HT

INSP INSPEC ECT T HEA HEATE TER R RES RESIS IST TAN ANCE CE OF HE HEA ATED TED OXY OXY-GEN SENSOR (a) Disco Disconne nnect ct the oxygen oxygen sensor sensor connec connector tor.. (b) Using Using an o ohmm hmmete eterr, measu measure re the the resi resista stance nce bet betwee ween n terterminals +B and HT. Resistance: 11 – 16 Ω at 20 C (68 F) If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) (c) Reco Reconn nnec ectt the the oxyg oxygen en sen senso sorr conn connec ecto torr. 2. INSP INSPEC ECT T OPE OPERA RATI TION ON OF HE HEA ATED TED OXY OXYGE GEN N SENSENSOR (See page DI–75 DI–75)) °

S05303

AuthorĂ:

°

DateĂ:

1496

SF–64 SFI (5S–FE) – ENGINE CONTROL MODULE (ECM)

ENGINE CONTROL MODULE (ECM) SF0EL–03

COMPONENTS

No.2 Instrument Lower Panel

ECM

ECM Connector

Under Cover

Cowl Side Trim Front Door Inside Scuff Plate

S06018

AuthorĂ:

DateĂ:

1497

SF–65 SFI (5S–FE) – ENGINE CONTROL MODULE (ECM) SF0EM–03

INSPECTION 1. 2. 3.

REMOVE ECM INSPECT ECM (See page DI–22 DI–22)) REINSTALL ECM

AuthorĂ:

DateĂ:

1498

SF–66 SFI (5S–FE) – FUEL CUT RPM

FUEL CUT RPM

SF0EN–03

INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature.

2. (a) (b) (c)

CONN CONNEC ECT T TOYO TOYOT TA HAN HAND– D–HE HELD LD TEST TESTER ER OR OBDI OBDIII SCAN TOOL Remov Re move e the the fuse fuse cove coverr o on n the the inst instrum rument ent pan panel. el. Conne Con nect ct a TOYO TOYOT TA hand– hand–he held ld teste testerr or OBDI OBDIII scan scan tool tool to the DLC3. Please Please refer refer to the the TOYOT TOYOTA A hand– hand–hel held d teste testerr or OBDII OBDII scan tool operator’s manual for further details.

S05331

3. (a) (b) (b) (c)

Sound Scope S05304

INSP INSPEC ECT T FU FUEL CU CUT T RP RPM OP OPER ERA ATION TION Increa Increase se the the engi engine ne spe speed ed tto oa att least least 2,5 2,500 00 rpm. rpm. Chec Ch eck k for for inj injec ecto torr oper operat atin ing g noi noise se.. Check Check that that when when the the thro throttl ttle e lever lever is rele release ased, d, inje injecto ctorr opoperation noise stops momentarily and then resumes.

HINT: Measure with the A/C OFF. Fuel return speed: 1,500 rpm 4. DISC DISCON ONNE NECT CT TOYO TOYOT TA HA HAND ND–H –HEL ELD D TEST TESTER ER OR OBDII SCAN TOOL

AuthorĂ:

DateĂ:

1499

SF–1 SFI (1MZ–FE) – SFI SYSTEM

SFI SYSTEM

SF078–03

PRECAUTION 1.

BEFOR EFORE E WOR WORKI KIN NG ON ON FU FUEL SYSTE YSTEM M, DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY BATTERY

HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (–) terminal cable is removed from the battery. Therefore, if necessary, necessary, read the diagnosis before removing the negative (–) terminal cable from the battery. 2. DO NOT NOT SMO SMOKE KE OR WORK WORK NE NEAR AR AN OPEN OPEN FLAM FLAME E WHEN WORKING ON FUEL SYSTEM 3. KEEP KE EP GASO GASOLI LINE NE AWAY FRO FROM M RUB RUBBE BER RO OR R LEATHER PARTS 4. MAINT INTENANCE P PR RECAUTIONS (a) In event event of engin engine e misfi misfire, re, thes these e preca precauti ution ons s should should be taken. (1) Ch Check eck prop proper er conn connect ection ion to batt battery ery termi terminal nals, s, etc. etc. (2) Aft After er repa repair ir work work,, ch check eck tha thatt the the ignit ignition ion coil coil te termi rmi-nals and all other ignition system lines are reconnected securely. (3) When When clean cleanin ing g the the engi engine ne compa compartm rtment ent,, be espeespecially careful to protect the electrical system from water. (b) Precau Precautio tions ns when when handl handling ing the oxyge oxygen n sens sensor or.. (1) (1) Do not allow allow the oxygen oxygen sensor sensor to drop drop or or hit hit against an object. (2) Do not allow allow the sensor sensor to come come into into cont contact act with with water. 5. IF VEH VEHIC ICLE LE IS EQUI EQUIPP PPED ED WITH WITH A MOB MOBIL ILE E RAD RADIO IO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 6. AIR INDUCTION SYSTEM (a) Separa Separatio tion n of the eng engine ine oil dipsti dipstick, ck, oil oil fille fillerr cap, cap, PCV hose, etc. may cause the engine to run out of tune. (b) Discon Disconnec nectio tion, n, loosen looseness ess or or cracks cracks in in the part parts s of the the air air induction system between the throttle body and cylinder head will allow air suction and cause cause the engine to run out of tune. 7. ELECTRONIC CO CONTROL SY SYSTEM (a) Before Before remov removing ing SFI wiri wiring ng con connec nector tors, s, termi terminal nals, s, etc., etc., first disconnect the power by either turning the ignition switch to LOCK or disconnecting the negative (–) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (–) terminal cable from the battery.

AuthorĂ:

DateĂ:

1500


(b) (c)

(d)

(e) (e) (f)

(g) (h)

When insta installi lling ng the the batt battery ery,, be espe especia cially lly care careful ful n not ot to inincorrectly connect the positive (+) and negative (–) cables. Do not not p perm ermit it part parts s to rece receive ive a sever severe e impac impactt durin during g reremoval or installation. Handle all SFI parts carefully, especially the ECM. Be carefu carefull during during trou trouble blesho shooti oting ng as ther there e are num numero erous us transistor circuit, and even slight terminal contact can cause further troubles. Do not not ope open n the the EC ECM Mc cov over er.. When When inspe inspecti cting ng duri during ng rain rainy y weath weather er,, take take care care to preprevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts Parts should should be replac replaced ed as an assemb assembly ly.. Care Ca re shoul should d be take taken n wh when en p pull ulling ing out out and insert inserting ing wirwiring connectors. (1) (1) Re Rele lease ase the the lock lock and and pull pull out out the con conne necto ctorr, pullin pulling g on the connectors. (2) Fully Fully inser insertt the conne connecto ctorr and and ch chec eck k that that it is is locke locked. d.

(i)

Use SST for inspec inspectio tion no orr ttest est of the inject injector or or its wiring wiring connector. SST 09842–30070

8. (a)

FUEL SYSTEM When When discon disconnec nectin ting g the the high high ffue uell press pressure ure line, line, a large large amount of gasoline will spill out, so observe these procedures: (1) (1) Disc Discon onne nect ct the the fuel fuel pum pump p con conne nect ctor or.. (2) Start Start the the e engi ngine ne.. Af After ter the eng engine ine has has stopp stopped ed on its own, turn the ignition switch to LOCK.

SST

FI2553

Fuel Pump Connector

S04600

(3) (3) (4) (4) (5) (5) (6) (6)

Plug

Put a con Put conta tain iner er und under er the the conn connec ecti tion on.. Slow Slowly ly loos loosen en the the conn connec ecti tion on.. Disc Discon onne nect ct tthe he conn connec ecti tion on.. Plug Plug the the con conne nect ctio ion n wi with th a rub rubbe berr plug plug..

S05039

AuthorĂ:

DateĂ:

1501


(b)

When When conne connecti cting ng the the unio union n bolt bolt on on the the high high pres pressur sure e pipe pipe union, observe these procedures: (1) (1) Alwa Always ys use use 2 new new gas gaske kets ts.. (2) (2) Tight ighten en the the uni union on bolt bolt by hand hand.. (3) Tighten ighten the union union bol boltt to the specif specified ied torque torque.. Torque: 32.5 N·m (330 kgf·cm, 24 ft·lbf)

New Gasket S05054

(c)

Fulcrum Length 30 cm SST

FI1654

New O–Ring

CORRECT

Grommet Injector WRONG

When When connect connecting ing the the flar flare e nut nut on the high high pres pressur sure e pipe pipe union, observe these procedures: (1) Apply Apply a ligh lightt coat coat of of en engin gine e oil oil to the the fflar lare e nu nut, t, and and tighten the flare nut by hand. (2) (2) Using Using SST SST, tighte tighten n the flar flare e nut to to specif specified ied tor torque que.. SST 09631–22020 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) for using SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

(d) (d)

Observ Observe e these prec precau autio tions ns when when remo removin ving g and inst instal alliling ng the injectors. (1) (1) Ne Neve verr reus reuse e the the O–ri O–ring ng.. (2) When When placin placing g a new new O–ri O–ring ng on the the inje injecto ctorr, ta take ke care not to damage it in any way. (3) Co Coat at a new O–ring O–ring with with spind spindle le oil or gaso gasolin line e be be-fore installing–never use engine, gear or brake oil.

FI6372 FI6372

AuthorĂ:

DateĂ:

1502


California A/T Delivery Pipe

(e)

Install Install the inj inject ector or to the delive delivery ry pipe pipe and intak intake e ma mani nifol fold, d, as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manmanifold touches an O–ring of the injector.

(f)

Observ Observe e thes these ep prec recau autio tions ns wh when en discon disconnec nectin ting g the the fue fuell tube connector (quick type). (1) Ch Check eck if ther there e is any dirt dirt like like mu mud d on the pipe pipe a and nd around the connector before disconnecting them and clean the dirt away. (2) (2) Be sure sure to disc discon onne nect ct with with hand hands. s.

O–Ring

Insulator Grommet Spacer

O–Ring Except California A/T Delivery Pipe

O–Ring

Insulator Grommet Spacer

O–Ring B00630

(3)

(4)

When When the the conne connecto ctorr and and the the pipe pipe are stuck, stuck, pinch pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect Inspect if ther there e is any any d dir irtt or the the llik ikes es o on n the the seal seal sur sur-face of the disconnected pipe and clean it away.

S04583

(5)

Vinyl Bag

Preven Preventt the discon disconne necte cted dp pipe ipe and and conne connecto ctorr from from damaging and mixing foreign objects by covering them with a vinyl bag.

S05040

AuthorĂ:

DateĂ:

1503


(g) Retainer

Observ Observe e these these preca precauti ution ons s wh when en conn connect ectin ing g the the fuel fuel tube connector (quick type). (1) Do not reuse reuse the the reta retaine inerr remov removed ed from from the pipe. pipe. (2) Must use use han hands ds withou withoutt us using ing too tools ls whe when n to remove remove the retainer from the pipe. (3) Ch Check eck ifif there there is any any dama damage ge or or forei foreign gn obj object ects s on the connected part of the pipe.

S05382

(4) Click Sound

(5)

(6) (6)

S05050

(h)

TOYOTA Hand–Held Tester

S05358

Match Match the axis axis of of the conn connec ecto torr with with axi axis s of the pipe pipe,, and push in the connector until the retainer makes a ”click” sound. In case that the connections is tight, apply little amount of new engine oil on the tip t ip of the pipe. After Aft er havin having g finis finished hed the connec connectio tion, n, chec check k if the pipe and the connector are securely connected by pulling them. Chec Ch eck k ifif the there re is any any fue fuell lea leaka kage ge..

Observ Observe e th these ese precau precautio tions ns when when han handli dling ng nylo nylon n tu tube. be. (1) Pay attent attention ion not to turn turn the conne connecte cted d pa part rt of of the the nylon tube and the quick connector with force when connecting them. (2) (2) Pa Pay y at atte tent ntio ion n not not to kin kink k th the e ny nylo lon n tube tube.. (3) Do not not remo remove ve the the EPDM EPDM prot protect ector or on the out outsid side e of the nylon tube. (4) Must Must not not close close the piping piping with with the the nylo nylon n tube tube by bending it.

(i) (i)

Check Chec k that that ther there e are are no ffue uell leak leaks s afte afterr doin doing g main mainte te-nance anywhere on the fuel system. (1) Co Conn nnect ect a TOYOTA OYOTA han hand– d–hel held d te teste sterr to the the D DLC3 LC3.. (2) Turn the the igni ignitio tion n switc switch h ON and and push push the TOYOT TOYOTA A hand–held tester main switch ON. NOTICE: Do not start the engine. (3) Select Select the the active active test test mode mode on the the TOYOT TOYOTA A hand– hand– held tester. (4) Please Please ref refer er to the the TOYOT TOYOTA A hand– hand–hel held d tester tester ope operrator’s manual for further details. (5) If yo you u have have n no o TOYO TOYOT TA hand–h hand–held eld test tester er,, conne connect ct the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6) (6) Ch Check eck tha thatt there there are no leaks leaks from from any part part of the fuel system. (7) (7) Turn urn the the igni igniti tion on swit switch ch to LOCK LOCK.. (8) Disco Disconne nnect ct th the e TOYO TOYOT TA hand hand–h –hel eld d tester tester fro from m the DLC3. AuthorĂ:

DateĂ:

1504

SF–6 SFI (1MZ–FE) – FUEL PUMP

TOYOTA Hand Held Tester

FUEL PUMP

SF079–04

ON–VEHICLE INSPECTION 1. (a) (b)

S05358

CHECK FU FUEL PU PUMP OP OPERATION Conne Co nnect ct a TOYOT TOYOTA A hand– hand–hel held d te teste sterr to the DL DLC3. C3. Turn Turn the igniti ignition on swi switch tch ON and and push push the TOYOT TOYOTA A hand– hand– held tester main switch ON. NOTICE: Do not start the engine. (c) Select Select the ACTIVE ACTIVE TEST TEST mode mode on the TOYOT TOYOTA A ha hand– nd– held tester. (d) Pleas Please e refer refer to the the TOYO TOYOT TA hand– hand–hel held d tester tester oper operato ator’s r’s manual for further details. (e) If you you have have n no o TOYO TOYOT TA hand–h hand–held eld test tester er,, connec connectt the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See step 7)

(f)

S05353

HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check these parts: Fusible link Fuses EFI main relay Fuel pump ECM Wiring connections (g) (g) Turn urn the the igni igniti tion on swit switch ch OFF OFF. (h) (h) Disco Disconne nnect ct the the TOYO TOYOT TA hand– hand–hel held d teste testerr from from the the DLC3.

2. (a) (b)

Fuel Tube Connector

Check Check that that ther there e is is p pres ressur sure e in in the the fuel fuel inlet inlet hose hose from from the fuel filter.

(c)

CHECK FUEL PRESSURE Check Ch eck the batte battery ry posi positiv tive e volta voltage ge is is above above 12 V. V. Disco Disconne nnect ct the the ne negat gative ive (–) termin terminal al cabl cable e from from the the ba batttery. Purcha Purchase se the new new No.1 No.1 fue fuell p pipe ipe and and ta take ke out out tthe he fue fuell tube connector from its pipe. Part No. 23801–20041

S05359

AuthorĂ:

DateĂ:

1505


(d) (d)

Remo Re move ve the the fue fuell hos hose e cla clamp mp..

Fuel Hose Clamp

S06086

(e)

S05352

Disco Disconne nnect ct the No.1 No.1 fue fuell pipe pipe (fue (fuell tube tube conn connect ector) or) from from the fuel filter outlet. CAUTION: D Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1) D As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. (f)

SST (Hose) SST Retainer No.1 Fuel Pipe

SST

Fuel Tube Connector SST (Hose) S05364

Instal Installl SST SST (pres (pressur sure e gau gauge) ge) as shown shown in the illust illustrat ration ion by using SST and fuel tube connector. SST SST 0926 09268– 8–41 4104 047, 7, 09268 09268–4 –412 1250 50,, 0926 09268– 8–45 4501 012 2 (g) (g) Wipe Wipe off off any any spla splatt tter ered ed gaso gasoliline ne.. (h) Re Recon conne nect ct the negat negative ive (–) (–) termin terminal al cable cable to the the batte battery ry.. (i) (i) Conn Co nnec ectt the TOYO TOYOT TA han hand d hel held d tes teste terr to the the DLC DLC3. 3. (See step 1. check fuel pump operation (a) to (e)) (j) (j) Mea easu sure re the the fuel fuel pre pressur ssure. e. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm 2, 44 – 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections Fuel pump Fuel filter Fuel pressure regulator (k) (k) Disco Disconne nnect ct the the TOYO TOYOT TA hand– hand–hel held d teste testerr from from the DLC3. (l) Start th the engine. (m) Mea Measur sure e the the fue fuell pres pressur sure e at at idle idle.. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm 2, 44 – 50 psi) (n) Stop top the engine. (o) Ch Check eck that that the fue fuell press pressure ure remain remains s as specif specified ied for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.

AuthorĂ:

DateĂ:

1506


(p)

After checki After checking ng fuel fuel pres pressur sure, e, disco disconn nnect ect the the neg negati ative ve (–) (–) terminal cable from the battery and carefully remove the SST and fuel tube connector to prevent gasoline from splashing. SST SST 0926 09268– 8–41 4104 047, 7, 0926 09268– 8–41 4125 250, 0, 092 09268 68–4 –450 5012 12

(q) Re Recon conne nect ct the the No.1 No.1 fuel fuel pip pipe e (fuel (fuel tube tube connec connector tor). ). CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1)

S05351

(r)

Fuel Hose Clamp

S06086

Ohmmeter 5

4

Surely Surely instal installl the the fue fuell h hose ose clamp clamp to the fue fuell filte filterr with with ”click” sound. (s) After After install installing ing the clamp, clamp, chec check k that that the the clam clamp p is is fixe fixed d by by pulling up the clamp. (t) Recon Re conne nect ct the nega negativ tive e (–) (–) termi termina nall cable cable to the the bat batter tery y. (u) (u) Check eck ffo or fue fuel lea leaks. ks. 3. REMOVE RE REAR SE SEAT CU CUSHION 4. REMOV EMOVE E FLO FLOOR OR SER SERVICE ICE HO HOLE COVE OVER 5. DISC DISCON ONNE NECT CT FUEL FUEL PU PUMP MP & SEN SENDE DER R GAU GAUGE GE CONNECTOR 6. INSP INSPEC ECT T FU FUEL PUMP RE RESI SIST STA ANCE Using an ohmmeter, ohmmeter, measure the resistance between terminals t erminals 4 and 5. Resistance: 0.2 – 3.0 Ω at 20 C (68 F) If the resistance is not as specified, replace the fuel pump. °

°

S04508

5

Battery

4

S04509

7. INSP INSPEC ECT T FUE FUEL PU PUM MP OPER PERATION ION Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (–) lead to terminal 5. Check that the fuel pump operates. NOTICE: D These tests must be done quickly (within 10 seconds) to prevent the coil burning out. D Keep the fuel pump as far away from the battery as possible. Always do the switching at the battery side. D AuthorĂ:

DateĂ:

1507


If operation is not as specified, replace the fuel pump or lead wire. 8. RECO RE CONN NNEC ECT T FUE FUEL L PUM PUMP P & SEND SENDER ER GAUG GAUGE E CONNECTOR 9. REIN RE INST STAL ALL L FLO FLOOR OR SER SERVICE VICE HOLE HOLE COVE COVER R 10. 10. RE REIN INST STAL ALL L REA REAR R SEA SEAT T CUS CUSHI HION ON

AuthorĂ:

DateĂ:

1508

SF–10 SFI (1MZ–FE) – FUEL PUMP SF07A–02

COMPONENTS Type A

Rear Seat Cushion



x8 4 (40, 35 in.·lbf)



Fuel Hose

Fuel Pump Connector

Fuel Pump Assembly

Fuel Pump D

Gasket Fuel Pump Filter

D

Clip

Rubber Cushion N·m (kgf·cm, ft·lbf) : Specified torque D Non–reusable part

B06401

AuthorĂ:

DateĂ:

1509


Type B

Rear Seat Cushion



x8

4 (40, 35 in.·lbf)

Fuel Sender Gauge


Fuel Pump Flange Fuel Tank Vent Tube Set Plate D

O–Ring

Fuel Filter

Fuel Pump Assembly Fuel Pump

Lead Wire

Housing

Gasket

D

Fuel Pump Filter

D

Clip

Rubber Cushion ”C” Bracket N·m (kgf·c (kgf·cm, m, ft·lbf ft·lbf)) : Specifie Specified d torque torque D

Non–reusable part

B06394

AuthorĂ:

DateĂ:

1510

SF–12 SFI (1MZ–FE) – FUEL PUMP SF07B–04

REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. REMOVE RE REAR SE SEAT CU CUSHION 2. REMOV EMOVE E FLO FLOOR OR SER SERVICE ICE HO HOLE COVE OVER (a) (a) Take ake out out the the flo floor or carp carpet et.. (b) (b) Re Remo move ve the the ser servi vice ce hole hole cove coverr. HINT: At the time of installation, plaese refer to the following items. Check for fuel leakage. 3. DISC DISCON ONNE NECT CT FUEL FUEL PU PUMP MP & SEN SENDE DER R GAU GAUGE GE CONNECTOR 4. REMOV EMOVE EN NO. O.1 1 FU FUEL TAN ANK K PR PROTE OTECTOR CTOR Remove the 2 bolts and No.1 fuel tank protector. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) in.·l bf)

5.

S04583

DISC DISCON ONNE NECT CT FUE FUEL L TUB TUBE E (FU (FUEL EL TUBE TUBE CONN CONNEC EC-TOR) CAUTION: Perform disconnecting and connecting operations of D the fuel tube connector (quick type) after observing the precautions. (See page SF–1) D As there is retained pressure in the fuel pipe line, prevent it from splashing inside the vehicle compartment. 6. (a)

Vinyl Bag

S04592

REMOVE REMO VE FUE FUEL L PUM PUMP P ASS ASSEM EMBL BLY Y FRO FROM M FUE FUEL L TAN TANK K Remov Re move e the 6 bolt bolts s and and fuel fuel tank tank vent vent tube tube set set plat plate. e. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) in.·l bf) (b) (b) Pu Pullll out out the the fuel fuel pump pump asse assemb mbly ly.. (c) (c) Re Remo move ve the the gas gaske kett from from the the pump pump a ass ssem embl bly y. NOTICE: D Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should D not bent. HINT: At the time of installation, plaese refer to the following items. Install a new gasket to the pump assembly.

AuthorĂ:

DateĂ:

1511

SF–13 SFI (1MZ–FE) – FUEL PUMP SF07C–03

DISASSEMBLY

Type B

1. 2. 3.

DISC ISCONN ONNEC ECT T FUEL FUEL PU PUMP MP CONN ONNEC ECT TOR TYPE B: DISCONNECT GROUND PLATE TYPE B: DISCONNECT FUEL SENDER GAUGE CONNECTOR

S06028

4.

Type A

(a) (b) (c) Pull

Type A: REMOVE FUEL PUMP FROM FUEL PUMP BRACKET Pull Pull off off the the lowe lowerr side side of of th the e fu fuel el pump pump from from the the pump pump bracket. Disconne Disconnect ct the fue fuell hose hose from from the the fuel fuel pum pump, p, and and remove remove the fuel pump. Remov Re move e the the rubber rubber cushio cushion n from from the fue fuell pump pump..

S04603

5.

Type B: REMOVE FUEL SENDER GAUGE Push down the portion of A with a finger, finger, and push up the sender gauge. NOTICE: Be careful that the arm of the sender gauge should not bent.

Type B

A Push S06033

6.

Type B

Type B: REMOVE FUEL FILTER Remov Re move e th the e screw screw,, and and pu pullll out out th the e fu fuel el filt filter er.. Remo Re move ve the the O–r O–rin ing g from from the the fue fuell filt filter er..

(a) (b) (b) HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip. S06050

7.

TYPE B: REMOVE FUEL PUMP FLANGE Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the t he fuel filter.

Type B

(2)

(3) (1)

S06030

AuthorĂ:

DateĂ:

1512


8.

Type B

Type B: REMOVE FUEL PUMP LEAD WIRE

S06027

9.

Type B (3) (1) (2)

Type B: REMOVE ”C” BRACKET, RUBBER CUSHION AND FUEL PUMP Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration.

S06029

10. REMOVE REMOVE FUEL FUEL PUMP PUMP FILTER FILTER FROM FROM FUEL FUEL PUMP PUMP (a) Using Using a smal smalll scre screwdr wdrive iverr, remov remove e the the clip clip.. (b) (b) Pu Pull ll out out the the pump pump filt filter er.. HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip.

FI6376

AuthorĂ:

DateĂ:

1513

SF–15 SFI (1MZ–FE)

–

FUEL PUMP SF07D–01

REASSEMBLY Reassembly is in the reverse order of disassembly. (See page SF–13)

AuthorĂ:

DateĂ:

1514


–

FUEL PUMP SF07E–01


AuthorĂ:

DateĂ:

1515

SF–17 SFI (1MZ–FE) – FUEL PRESSURE REGULATOR

FUEL PRESSURE REGULATOR SF07F–03

COMPONENTS Type A

Rear Seat Cushion



x8 4 (40,35 in.·lbf)



Fuel Pump Assembly

D

Gasket


O–Ring

D

D

O–Ring

Fuel Filter N·m (kgf·cm, ft·lbf) : Specified torque D Non–reusable part

B06392

AuthorĂ:

DateĂ:

1516

SF–18 SFI (1MZ–FE) – FUEL PRESSURE REGULATOR

Type B

Rear Seat Cushion


x8


4 (40, 35 in.·lbf)



Fuel Pump Assembly

D D

O–Ring

Gasket


D

O–Ring

Fuel Filter


B06393

AuthorĂ:

DateĂ:

1517

SF–19 SFI (1MZ–FE) – FUEL PRESSURE REGULAT REGUL ATOR OR SF07G–03

REMOVAL 1.

REMOVE REMO VE FUE FUEL L PUMP PUMP ASS ASSEM EMBL BLY Y FROM FROM FUE FUEL L TAN TANK K (See page SF–12)

2. (a)

REMOVE FUEL FILTER Remov Remove e the the screw screw,, and and pull pull out out the the fuel fuel filt filter er.. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) Remo Remove ve the the O–r O–rin ing g from from the the fue fuell filt filter er..

(b) (b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the fuel filter. S04591

3. (a)

REMOVE REMO VE FUEL FUEL PR PRES ESSU SURE RE RE REGU GULA LAT TOR Remov Remove e the scre screw w, and pull pull out out the the pressu pressure re regu regulat lator or.. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) Remov Remove e the the O–rin O–ring g from from the the pres pressur sure e regul regulato atorr.

(b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the pressure regulator. S04590

AuthorĂ:

DateĂ:

1518


–

FUEL PRESSURE REGU LATOR LATOR SF07H–01


AuthorĂ:

DateĂ:

1519

SF–21 SFI (1MZ–FE) – INJECTOR

INJECTOR

SF07I–03

ON–VEHICLE INSPECTION

5 mm Hexagon Wrench

1. (a) (b)

Clip

REMOVE V– V–BANK CO COVER Using Using a 5 mm hexago hexagon n wren wrench, ch, remove remove the 2 cap cap nuts. nuts. Disco Disconne nnect ct the the 2 clips clips,, and and remov remove e the V–bank V–bank cover cover..

S04528

California A/T

2. INSP INSPEC ECT T IIN NJE JECT CTOR OR OPER OPERA ATION TION Check operation sound from each injector. (1) With With th the e en engin gine e runni running ng o orr crank cranking ing,, use use a sou sound nd scope to check that there is normal operating noise in proportion to engine speed. (2) If you you h have ave no sound sound scope scope,, yo you u ca can n ch check eck the in jector operating vibration with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM.

Sound Scope

Except California A/T Sound Scope

B00623

3. (a) (a) (b)

INSP INSPEC ECT T IIN NJE JECT CTOR OR RESIST SISTA ANC NCE E Disc Discon onne nect ct the the inje inject ctor or con conne nect ctor or.. Using Using an ohm ohmmet meter er,, measu measure re the the resi resistan stance ce betw between een the terminals. Resistance: 13.4 – 14.2 Ω at 20 C (68 F) If the resistance is not as specified, replace the injector. (c) (c) Re Reco conn nnec ectt the the inje inject ctor or conn connec ecto torr. 4. REINSTALL V–BANK COVER HINT: For fixing the V–bank cover, push on the cover until a ”click” is felt.

California A/T Ohmmeter

°

Except California A/T

°

Ohmmeter

B00624

AuthorĂ:

DateĂ:

1520

SF–22 SFI (1MZ–FE) – INJECTOR SF07J–03

COMPONENTS Air Intake Chamber Stay 19.5 (200, 14)

12 (120, 9)

39 (400, 29)

PS Pressure Tube Gasket No.2 EGR Pipe Throttle Position Sensor Connector D Gasket EGR Valve Position Brake Booster Sensor Connector D

No.1 Engine Hanger 43 (440, 32)

VSV Connector for EGR Engine Wire

V–Bank Cover

Accelerator Cable

Vacuum Hose

IAC Valve Connector

Throttle Cable

VSV Connector for EVAP Ground Cable

Air Cleaner Hose

Ground Strap Purge Hose

DLC1 PCV Hose Air Intake Chamber Assembly

D

EGR Gas Temperature Sensor Connector

Vacuum Hose

Gasket

Water Bypass Hose

VSV Connector for ACIS

Air Assist Hose and Pipe 19.5 (200, 14)

10 (100, 7)

D

Spacer D

O–Ring

D

Grommet

Injector

Injector Connector

D D

Retainer

California A/T Injector

Insulator O–Ring High–Tension Cord Set

N·m (kgf·cm (kgf·cm,, ft·lbf) ft·lbf) : Specifi Specified ed torque torque D Non–reusable part

B06391

AuthorĂ:

DateĂ:

1521

SF–23 SFI (1MZ–FE) – INJECTOR SF07K–04

REMOVAL 1. 2.

REMOVE AIR CLEANER HOSE REMO RE MOVE VE AIR AIR INT INTAK AKE E CHA CHAMB MBER ER AS ASSE SEMB MBL LY (See page EM–32)

3.

DISC DISCON ONNE NECT CT INJE INJECT CTOR OR CONN CONNEC ECT TORS ORS

4. (a) (b)

REMOV EMOVE E AIR AIR ASSIS SSIST T HOS HOSE ES AN AND P PIP IPE E Disco Disconne nnect ct the air assist assist pipe pipe from from the the brac bracket ket on the the No.1 fuel pipe. Remov Re move e th the e air air assis assistt hoses hoses from from the the intak intake e ma manif nifold old..

5. (a) (a)

DISCONNECT NO NO.1 FU FUEL PI PIPE Remo Re move ve the the fue fuell hos hose e cla clamp mp..

S04505

S04498

Fuel Hose Clamp

S06086

(b)

S05352

Disco Disconne nnect ct the No.1 No.1 fue fuell pipe pipe (fue (fuell tube tube conn connect ector) or) from from the fuel filter outlet. CAUTION: Perform disconnecting operations of the fuel tube D connector (quick type) after observing the precautions. (See page SF–1) D As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment.

AuthorĂ:

DateĂ:

1522


B01020

6. REMO RE MOVE VE D DEL ELIV IVER ERY Y PIP PIPES ES AN AND D INJ INJEC ECTO TORS RS NOTICE: D Be careful not to drop the injectors when removing the delivery pipes. D Pay attention to put any hung load on the injector to and from the side direction. (a) Re Remov move e th the e 5 bolts bolts and and d deli eliver very y pipes pipes tog togeth ether er with with the 6 injectors and No.1 fuel pipe. (b) Re Remov move e th the e 4 spacer spacers s from from the the intake intake man manifo ifold. ld. (c) Pull Pull out out the 6 inje injecto ctors rs from from the the deliv delivery ery pipes. pipes. (d) Re Remov move e the the 2 O–rin O–rings gs a and nd 2 gromm grommets ets from from each each injec injec-tor.

AuthorĂ:

DateĂ:

1523

SF–25 SFI (1MZ–FE) – INJECTOR SF07L–04

INSPECTION

California A/T Fuel Tube Connector SST (Hose) SST (Union) SST (Clamp) Injector

1. INSP INSPEC ECT T INJE INJECT CTOR OR INJ INJEC ECTI TION ON CAUTION: Keep injector clear of sparks during the test.

Fuel Filter (On Vehicle)

Except California A/T Fuel Tube Connector SST (Hose) SST (Union) SST (Clamp) Injector

Fuel Filter (On Vehicle) B01919

(a) Fuel Tube Connector

Purcha Purchase se the new new No.1 No.1 fuel fuel pipe pipe and and ta take ke out out the the fuel fuel tube connector from its pipe. Part No. 23801–20041

S05359

(b)

Fuel Tube Connector

SST (Hose)

Fuel Filter S05357

Connect Conne ct SST (hos (hose e ) and and ffuel uel tub tube e conne connecto ctorr to the fue fuell filter outlet. SST 09268–41047 CAUTION: Preform connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1) HINT: Use the vehicle fuel filter.

AuthorĂ:

DateĂ:

1524


California A/T

SST (Hose)

(c) (d)

SST (Union) O–Ring SST (Clamp)

Instal Installl the the g grom rommet met and and O–Rin O–Ring g to the inject injector or.. Conne Co nnect ct SST SST (union (union and hose) hose) to the the inje injecto ctorr, and hold hold the injector and union with SST (clamp). SST 09268–41047 Put the inject injector or into into a gradua graduated ted cylind cylinder er..

(e) HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.

Vinyl Tube Except California A/T SST (Hose) SST (Union) O–Ring SST (Clamp) Vinyl Tube B01914

TOYOTA Hand–Held Tester

S05358

(f) (f) (g)

Connec Conn ectt a TOY TOYOT OTA A hand hand–h –hel eld d test tester er to to the the DLC3 DLC3.. Turn Turn the igniti ignition on swi switch tch ON and and push push the TOYOT TOYOTA A hand– hand– held tester main switch ON. NOTICE: Do not start the engine. (h) Select Select the ACTIVE ACTIVE TEST TEST mode mode on the TOYOT TOYOTA A hand– hand– held tester. (i) Pleas Please e refer refer to the TOYOT TOYOTA A ha hand nd–he –held ld tester tester opera operator’ tor’s s manual for further details. (j) (j) If you you have have no TOYO TOYOT TA hand– hand–he held ld test tester er,, conn connec ectt the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6)

AuthorĂ:

DateĂ:

1525


(k)

Connect Conne ct SST SST (wir (wire) e) to to th the e inje injecto ctorr and and ba batte ttery ry for for 15 15 seseconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842–30070 Volume: 60 – 73 cm3 (3.4 – 4.5 cu in.) per 15 sec. Difference between each injector: 13 cm3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector.

California A/T

SST (Wire)

Battery Except California A/T

SST (Wire)

Battery California A/T

B01913

2. (a)


B00628

INSPECT LEAKAGE In th the e cond conditi ition on abo above, ve, discon disconnec nectt the the test test prob probes es of SST SST (wire) from the battery and check the fuel leakage from the injector. SST 09842–30070 Fuel drop: 1 drop or less per 12 minutes (b) (b) Turn urn the the igni igniti tion on swit switch ch OFF OFF. (c) Disco Disconne nnect ct the the ne negat gative ive (–) termin terminal al cabl cable e from from the the ba batttery. (d) (d) Re Remo move ve the the SST SST and and fue fuell tu tube be con conne nect ctor or.. SST SST 0926 09268– 8–41 4104 047, 7, 0984 09842– 2–30 3007 070 0 CAUTION: D Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1) D As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. (e) (e) Disco Disconne nnect ct the the TOYO TOYOT TA hand– hand–hel held d teste testerr from from the the DLC3.

AuthorĂ:

DateĂ:

1526

SF–28 SFI (1MZ–FE) – INJECTOR SF07M–04

California A/T

INSTALLATION

New Insulator

New O–Ring

New O–Ring

1. (a) (b)

INST INSTAL ALL L INJE INJECT CTOR ORS S AND AND DE DELI LIVE VER RY PIPE PIPES S Instal Installl new new in insul sulato atorr and and gromm grommet et to each each injec injector tor.. Apply Apply a light light coat coat of spin spindl dle e oil oil or gasol gasoline ine to 2 new O– rings and install them to each injector.

(c)

(e) (e)

Apply Apply a light light coat coat of spin spindle dle oil or gaso gasolin line e on the place place where a delivery pipe touches an O–ring of the injector. While While turni turning ng the the injec injector tor cloc clockwi kwise se and and count counterc erclo lockckwise, push it to the delivery pipes. Install the 6 injectors. Posi Po siti tion on the the inje inject ctor or conn connec ecto torr outwa outward rd..

(f)

Place Place the 4 spac spacers ers in positi position on on the intake intake ma manif nifol old. d.

New Grommet Except California A/T New Insulator

New O–Ring

New O–Ring

New Grommet B00629

California A/T

(d)

Turn Push Connector


Turn Push Connector

B00625

Spacer

Spacer

S04510

AuthorĂ:

DateĂ:

1527


(g) (h) (i) (j)

Apply Apply a light light coat coat of spin spindle dle oil or gaso gasolin line e on the the plac place e where a intake manifold touches an O–ring of the injector. Place Place the deliv delivery ery pipes pipes and and fuel fuel pipe pipe tog togeth ether er with with the 6 injectors in position on the intake manifold. Tem empor porari arily ly inst instal alll th the e4b bolt olts s ho holdi lding ng the deli deliver very y pipe pipes s to the intake manifold. Tem empor porari arily ly insta installll the the bolt bolt holdi holding ng the No No.1 .1 fuel fuel pipe pipe to the intake manifold.

B01021

(k) (k) Ch Chec eck k that that the the inje inject ctor ors s rota rotate te smoo smooth thly ly.. HINT: If injectors do not rotate smoothly, smoothly, the probable cause is incorrect installation of O–rings. Replace the O–rings. (l) (l) Posi Po siti tion on the the inje inject ctor or conn connec ecto torr o out utwa ward rd..

Rotate Outward

S04728

(m)

(n)

Tight Tighten en the 4 bolts bolts holding holding the the delive delivery ry pipes pipes to the the intak intake e manifold. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Tighten ighten the bolt bolt hol holdin ding g the the No.1 No.1 fuel fuel pipe pipe to the intake intake manifold. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf)

B01020

2. (a)

CONNECT NO NO.1 FUEL PIPE Align Align th the e align alignmen mentt marks marks (wh (white ite pain paint) t) on on the No. No.1 1 fu fuel el pipe.

Align S06525

(b)

Connect Conne ct the No.1 No.1 fue fuell pipe pipe (fue (fuell tube tube conn connect ector) or) to the the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precaution. (See page SF–1)

S05351

AuthorĂ:

DateĂ:

1528


(c) Fuel Hose Clamp

(d)

Surely Surely inst install all the fue fuell hose hose clam clamp p to the fue fuell filte filterr with with ”click” sound. After After installi installing ng the the clamp, clamp, chec check k that that the the c clam lamp p is is ffixe ixed d by by pulling up the clamp.

S06086

3. (a) (b) 4. 5.

S04498

6. 7.

INST INSTAL ALL L AIR AIR AS ASSI SIST ST HOSE HOSES S AN AND D PIPE PIPE Conne Co nnect ct the the air air assis assistt hoses hoses to the the intak intake e manif manifold old.. Instal Installl the air assist assist pipe pipe to the the brack bracket et on on the No. No.1 1 fuel fuel pipe. CONN ONNEC ECT T INJ INJE ECTOR CTOR CONN ONNEC ECT TORS ORS INST INSTAL ALL L AIR AIR INT INTAK AKE E CH CHAM AMBE BER R ASSE ASSEMB MBL LY (See page EM–57) INSTALL AI AIR CL CLEANER HO HOSE CHECK FO FOR FU FUEL LE LEAKS

AuthorĂ:

DateĂ:

1529

SF–31 SFI (1MZ–FE) – FUEL TANK AND LINE

FUEL TANK AND LINE SF07N–03

COMPONENTS CAUTION: Always use new gaskets when replacing the fuel tank or component parts. Apply the proper torque to all parts tightened. Heated Oxygen Sensor (Bank 1 Sensor 2) x8 No.1 Fuel Tank Tank Protector Fuel Tank Vent Tube Set Plate Fuel Pump

Location Locati on of Fuel Tank Tank Cushion HINT: D Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns. D After installing the heated oxygen sensor, check that the sensor wire is not twisted, if it is twisted, remove the heated oxygen sensor and reinstall it. Charcoal Canister

Fuel Inlet Pipe Shield

Fuel Tank Cap

Vent Line Hose Gasket

Fuel Outlet Tube Gasket

EVAP Line Hose

Fuel Inlet Hose

Fuel Inlet Pipe

Fuel Inlet Pipe Protector Fuel Tank

39 (400, 29)

Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) Fuel Tank Band

Heat Insulator

44 (450, 33) 56 (570, 41)

Gasket

Center Exhaust Pipe

56 (570, 41)

N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part

B06469

AuthorĂ:

DateĂ:

1530

SF–32 SFI (1MZ–FE) – FUEL TANK AND LINE SF07O–03

INSPECTION Crack

Leakage

Deformation

SST

BO0919

Use SST 28 N·m (285 kgf·cm, 21 ft·lbf)

INSPECT FUEL TANK AND LINE (a) Check Check the fue fuell line lines s for for crack cracks s or leakag leakage, e, and and all all conn connecections for deformation. (b) Check Check the fue fuell tank tank vap vapor or ven ventt syste system m hose hoses s and and conn connecections for looseness, sharp bends or damage. (c) Ch Check eck the the ffue uell tank tank for for defor deformat mation ion,, cracks cracks,, fuel fuel leaka leakage ge or tank band looseness. (d) Ch Check eck the filler filler neck neck for for damag damage e or fue fuell leaka leakage. ge. (e) Ho Hose se and and pipe pipe connec connectio tions ns are are as as show shown n in the the illu illustr straation. If a problem is found, repair or replace the parts as necessary.

Fulcrum Length 30 cm (11.81 in.) SST: 09631–22020 Z10162

2 – 7 mm (0.08 – 0.28 in.) Hose Pipe

Clip 0 – 3 mm (0 – 0.12 in.)

FU0041

AuthorĂ:

DateĂ:

1531

SF–33 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER

MASS AIR FLOW (MAF) METER SF07P–04

COMPONENTS MAF Meter Connector MAF Meter

D

D

Gasket

Non–reusable part

S04539

AuthorĂ:

DateĂ:

1532

SF–34 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER SF07Q–03

REMOVAL REMOVE MAF METER (a) (a) Disc Disconn onnec ectt the the MA MAF F met meter er conne connect ctor or.. (b) (b) Remov Remove e the the 2 bol bolts ts,, MAF MAF met meter er and and gas gaske ket. t. HINT: At the time of installation, please refer to the following items. Install a new gasket to the MAF meter. S04755

AuthorĂ:

DateĂ:

1533

SF–35 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER SF07R–03

Ohmmeter

INSPECTION 1. INSP INSPEC ECT T MAF METE ETER RESI RESIS STANCE ANCE Using an ohmmeter, ohmmeter, measure the resistance between terminals t erminals THA and E2. Resistance:

THA

E2

S04526

Terminals

Resistance

Temperature

THA – E2

14.6 – 17.8 kΩ

–20 C (–4 F)

THA – E2

2.21 – 2.69 kΩ

20 C (68 F)

THA – E2

0.29 – 0.35 kΩ

60 C (140 F)

°

°

°

°

°

°

If the resistance is not as specified, replace the MAF meter.

2. (a) (a) (b) (b) (c)

E2G VG Air

Voltmeter

S04756

INSP INSPEC ECT T MAF MAF METE METER R OP OPE ERATI RATION ON Conn Connec ectt the the MAF MAF met meter er conn connec ecto torr. Turn urn the the ign ignit itio ion ns swi witc tch hO ON. N. Using Using a volt voltmet meter er,, co conne nnect ct the the positi positive ve (+) (+) teste testerr probe probe to terminal VG, and negative (–) tester probe to terminal E2G. (d) Blow Blow air air into into the the MAF MAF mete meterr, and and check check tha thatt the voltag voltage e fluctuates. If operation is not as specified, replace the MAF meter. (e) (e) Turn urn the the igni igniti tion on swit switch ch OFF OFF. (f) (f) Disc Discon onne nect ct the the MAF MAF met meter er con conne nect ctor or..

AuthorĂ:

DateĂ:

1534

SF–36 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER SF07S–01


AuthorĂ:

DateĂ:

1535

SF–37 SFI (1MZ–FE) – THROTTLE BODY

THROTTLE BODY

SF07T–03

ON–VEHICLE INSPECTION 1. INSPECT TH THROTTLE BODY Check that the throttle linkage moves smoothly.

S04593

Vacuum Ohmmeter

2. (a) (a) (b) (c) (c) (d)

VTA E2 VC S04536

(e) (f) (f) 3. (a) (b)

INSP INSPEC ECT T THR THROTTL OTTLE E POSI POSITI TION ON SEN SENSO SOR R Disc Discon onne nect ct the the sens sensor or conn connec ecto torr. Disco Disconne nnect ct the the vacuu vacuum m hose hose from from the thrott throttle le body body.. Appl Ap ply y vac vacuu uum m to to the the thro throttl ttle e ope opene nerr. Using Using an an ohmm ohmmete eterr, measu measure re the the resi resista stance nce bet betwe ween en each terminal. Resistance: Throttle valve

Between

condition

terminals

Fully closed

VTA – E2

0.2 – 6.3 kΩ

Fully open

VTA – E2

2.0 – 10.2 kΩ

–

VC – E2 E2

2.5 – 5.9 5.9 kΩ

Resistance

Reconne Recon nect ct the vacuum vacuum hose hose to to th the e thro throttl ttle eb bod ody y. Reco Re conn nnec ectt the the sens sensor or conn connec ecto torr. INSPECT THROTTLE OPENER Allow Allow the engin engine e to warm warm up to to norma normall op oper erati ating ng tem tempe perarature. Check id idle speed. Idle speed: 700 ± 50 rpm

(c)

Plug

Disconnect

S04604

Disco Disconne nnect ct the vacuum vacuum hose hose from from tthe he thrott throttle le ope opener ner,, and plug the hose end. (d) (d) Ch Chec eck k th the e thro thrott ttle le ope opene nerr sett settin ing g sp spee eed. d. Throttle opener setting speed: 900 – 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. (e) Stop top the engine. (f) Recon Re conne nect ct the vacuum vacuum hose hose to the thrott throttle le opene openerr. (g) Start Start the engi engine ne and and chec check k that that the the idle idle speed speed retu returns rns to the correct speed.

AuthorĂ:

DateĂ:

1536

SF–38 SFI (1MZ–FE) – THROTTLE BODY SF07U–03

COMPONENTS D

Gasket

19.5 (200, 14)

Throttle Body Throttle Position Sensor Connector EGR Gas Temperature Sensor Bracket IAC Valve Connector

Water Bypass Hose Air Assist Hose Accelerator Cable

Throttle Cable (A/T) : Specified torque N·m (kgf·cm, ft·lbf) D Non–reusable part

Water Bypass Hose

Air Cleaner Hose

AuthorĂ:

S04741

DateĂ:

1537

SF–39 SFI (1MZ–FE) – THROTTLE BODY SF07V–03

REMOVAL 1. 2. 3. 4. (a) (a) (b) S04506

(a) (e) (c)

(b)

5. (a) (b) (b) (c) (d)

(d)

(e) (e)

DRAIN ENGINE COOLANT DISC ISCONN ONNEC ECT T ACC ACCELER LERATOR CA CAB BLE A/T: DISCONNECT THROTTLE CABLE REMOVE AIR CLEANER HOSE Disc Discon onne nect ct the the PC PCV V hose hose.. Loose Loosen n the 2 hose hose clamp clamps, s, and and remo remove ve the the a air ir clea cleane nerr hose. REMOVE THROTTLE BODY Disco Disconne nnect ct the the throt throttle tle posi positio tion n senso sensorr conne connecto ctorr. Disc Discon onne nect ct the the IAC IAC val valve ve con conne nect ctor or.. Disco Disconne nnect ct the wate waterr bypa bypass ss hos hose e (from (from the intake intake ma mannifold). Disco Disconne nnect ct the wate waterr bypas bypass s ho hose se (fro (from m the the water water inlet inlet housing). Disc Discon onne nect ct the the air air assi assist st hos hose. e.

S06123

(f) EGR Gas Temperature Sensor Bracket

Remove Remov e the 2 bolt bolts, s, 2 nut nuts, s, EGR EGR g gas as ttem empe pera ratu ture re sen senso sorr bracket, throttle body and gasket.

HINT: At the time of installation, please refer to the following items. Place a new gasket on the air intake chamber. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf)

S04527

AuthorĂ:

DateĂ:

1538

SF–40 SFI (1MZ–FE) – THROTTLE BODY SF07W–03

INSPECTION 1. (a)

S04582

Throttle Stop Screw

CLEAN TH THROTTLE BO BODY Using Using a soft soft brus brush h and carb carbure uretor tor clea cleane nerr, clean clean the the cast cast parts. (b) Using Using compr compress essed ed air air,, clean clean all all the pass passage ages s and aper aper-tures. NOTICE: To prevent deterioration, do not clean the throttle position sensor and IAC valve. 2. (a) (a) (b)

Vacuum

3. No Clearance Throttle Lever

INSPECT TH THROTTLE VALVE Appl Ap ply y vacu vacuum um to to the the thro throttl ttle e open opener er.. Check Check that ther there e is no no clea clearan rance ce betw betwee een n the the thrott throttle le sto stop p screw and throttle lever when the throttle valve is fully closed. INSP INSPEC ECT T THR THROTTL OTTLE E POS POSIT ITIO ION NS SEN ENSO SOR R (See page SF–37)

S04595

AuthorĂ:

DateĂ:

1539


–

THROTTLE BODY SF07X–01


AuthorĂ:

DateĂ:

1540

SF–42 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE

IDLE AIR A IR CONTROL CONT ROL (IAC) (IAC ) VAL VALVE VE

SF07Y–03

ON–VEHICLE INSPECTION 1. (a) (a)

E1

INSP INSPEC ECT T IA IAC VAL VALVE VE OPE OPERA RATI TION ON Init Initiial cond condiition tions: s: D Engine at normal operating temperature D Idle speed checked correctly D Transmission in neutral position D A/C switch OFF

(b)

DLC1 SST

TE1 DLC1 S04529

RSC +B RSO Ohmmeter

Using Using SST SST,, conne connect ct term termina inals ls TE1 TE1 and and E1 E1 of the DLC1. SST 09843–18020 (c) Aft After er engi engine ne spee speed d is kept kept at app approx rox.. 1,00 1,000 0 rpm rpm for for 5 seseconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) (d) Re Remo move ve the the S SST ST from from the the DLC DLC1. 1. SST 09843–18020 2. INSP INSPEC ECT T IAC IAC VALVE ALVE RE RESI SIST STAN ANCE CE NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the coils themselves. ”Cold” is from –10 C (14 F) to 50 C (122 F) and ”Hot” is from 50 C (122 F) to 100 C (212 F). (a) (a) Disc Discon onne nect ct the the IAC IAC val valve ve con conne nect ctor or.. (b) Using Using an ohmm ohmmete eterr, measu measure re the the resi resista stance nce bet betwee ween n terterminal +B and other terminals (RSC, RSO). Resistance: °

°

°

°

S04533

°

°

°

°

Cold

17.0 – 25.0 Ω

Hot

21.5 – 29.5 Ω

If resistance is not as specified, replace the IAC valve. (c) (c) Re Reco conn nnec ectt the the IAC IAC val valve ve conn connec ecto torr. 3. INSPECT AI AIR ASSIST SY SYSTEM (a) (a) Init Initiial cond condiition tions: s: D Engine at normal operating temperature Idle speed checked correctly D D Transmission in neutral position D A/C switch OFF

AuthorĂ:

DateĂ:

1541

SF–43 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE

E1

(b)

DLC1 SST

(c) (d)

Using Using SST SST,, co conne nnect ct termi terminal nals s TE1 and E1 o off the the DL DLC1. C1. SST 09843–18020 After Aft er engin engine e speed speed is kept kept at 900 900 – 1,3 1,300 00 rpm rpm for for 10 10 seseconds, check that it returns to idle speed. Stop top the engine.

TE1 DLC1 S04529

Plug

Disconnect Plug

S04531

(e)

Disconne Disconnect ct the air air assi assist st hos hose e from from the the air air pip pipe, e, and and blo block ck off the IAC valve exit and the entry to the pipe. (f) Start Start the the eng engine ine and check check tha thatt th the e idle idle speed speed reache reaches s 500 rpm or below (the engine may stall). If the t he idle does not reach 500 rpm or below, below, check for a leak between the air assist hoses, pipe and injectors. (g) (g) Re Remo move ve the the S SST ST from from the the DLC DLC1. 1. SST 09843–18020 (h) Re Recon conne nect ct the the air assist assist hose hose to to th the ea air ir pipe. pipe.

AuthorĂ:

DateĂ:

1542

SF–44 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE SF07Z–03

COMPONENTS D

Gasket 19.5 (200, 14)

Throttle Body Throttle Position Sensor Connector

Throttle Body

EGR Gas Temperature Sensor Bracket IAC Valve Connector

D

Gasket

IAC Valve

Water Bypass Hose Air Assist Hose Water Bypass Hose

Accelerator Cable) Throttle Cable (A/T) N·m (kgf· (kgf·cm, cm, ft·lbf) ft·lbf) : Speci Specified fied torque torque D Non–reusable part

Air Cleaner Hose

AuthorĂ:

S04742

DateĂ:

1543

SF–45 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE SF080–03

REMOVAL 1.


2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. HINT: At the time of installation, please refer to the following items. Place a new gasket on the throttle body.

P14340

AuthorĂ:

DateĂ:

1544


INSPECTION

RSC +B

INSPECT IAC VALVE OPERATION (a) Con Conne nect ct the posi positiv tive e (+) lead lead from from the bat batter tery y to termi terminal nal +B and negative (–) lead to terminal RSC, and check that the valve is closed.

Battery

Closed P14290

(b) +B RSC

Connect Conne ct the posi positiv tive e (+) lead lead from from the bat batter tery y to termi terminal nal +B and negative (–) lead to terminal RSO, and check that the valve is open. If operation is not as specified, replace the IAC valve.

Battery

Open P14289

AuthorĂ:

DateĂ:

1545



AuthorĂ:

DateĂ:

1546

SF–48 SFI (1MZ–FE) – ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS)

Vacuum Gage

ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) ON–VEHICLE INSPECTION

S05036

Approx. 27.6 kPa

SF083–03

INSPECT INTAKE AIR CONTROL VALVE (a) Using Using a 3–w 3–way ay conne connecto ctorr, conne connect ct vacuu vacuum m gaug gauge e to tthe he actuator hose. (b) Star tart the engine. (c) While While the the engine engine is idli idling, ng, check check that that the vacuum vacuum gau gauge ge needle does not move.

(d)

Rapidly Rapid ly depre depress ss the the accele accelerat rator or pedal pedal to to fully fully open open posi posi-tion and check that the vacuum gauge needle momentarily fluctuates up to approx. 26.7 kPa (200 mmHg, 7.9 in.Hg). (The actuator rod is pulled out.)

S05037

AuthorĂ:

DateĂ:

1547

SF–49 SFI (1MZ–FE) – ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF084–03

COMPONENTS

D

Gasket

Intake Air Control Valve

14.5 (145, 10)

DLC1 Bracket

DLC1

Actuator Vacuum Hose

Ground Strap

Ground Cable


B06467

AuthorĂ:

DateĂ:

1548


REMOVAL (2)

1. 2.

DISC DISCON ONNE NECT CT ACTU ACTUA ATOR VACUU ACUUM M HOSE HOSE DISC DISCON ONNE NECT CT DLC1 DLC1 FRO FROM DLC DLC1 1 BRA BRACK CKET ET

3. (a)

REMO REMOVE VE INT INTAKE AKE AIR AIR CONT CONTRO ROL L VALVE ALVE Remove Remo ve the 4 nuts nuts and and DLC DLC1 1 brac bracket ket,, and and disco disconn nnec ectt the the ground strap and cable. Remove Remo ve the intak intake e air air contr control ol val valve ve by by pryi prying ng a screw screwdri drivver between the intake air control valve and air intake chamber. Remove th the gasket.

(1)

B06470

(b)

(c) B06471

AuthorĂ:

DateĂ:

1549


INSPECTION 1. (a)

INSP INSPEC ECT T INT INTAK AKE E AIR AIR CONT CONTRO ROL L VAL VALVE VE With With 26.7 26.7 kPa kPa (200 (200 mmH mmHg, g, 7 7.9 .9 in.H in.Hg) g) of of vacuu vacuum m appl applied ied to the actuator, check that the actuator rod moves. (b) One minute minute after after app applyi lying ng the the vacu vacuum um in in (a), (a), chec check k that that the actuator rod does not return. If the operation is not as specified, replace the intake air control valve.

Vacuum S05041

Air

2. INSPECT VA VACUUM TANK LOCATION: The LH side member under the battery tray. (a) (a) Ch Chec eck k th that at air air flow flows s from from port port B to por portt A. (b) Ch Check eck tha thatt air air does does not flow flow from from port port A to port port B.

Air

S05689

Vacuum

(c)

Plug Plug port port B with with your your finge fingerr, an and d ap apply ply 26. 26.7 7 kPa kPa (200 (200 mmHg, 7.9 in.Hg) of vacuum to port A, and check that there is no change is vacuum after one minute. If the operation is not as specified, replace the vacuum tank. 3. INSP INSPEC ECT T VSV (Se (See page page SF– SF–60 60))

S05688

AuthorĂ:

DateĂ:

1550


INSTALLATION New Gasket

1. (a)

INST INSTAL ALL L INT INTAK AKE E AIR AIR CONT CONTRO ROL L VAL VALVE VE Instal Installl a new new gask gasket et to to the the air air inta intake ke cha chambe mberr.

(b) (c)

Apply Apply a ligh lightt co coat at o off engin engine e oil oil to the the rubb rubber er port portion ions. s. Apply Apply seal packi packing ng to to the posit positio ions ns of of the the in intak take e ai airr contr control ol valve shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent Instal Installl the inta intake ke air air contr control ol valv valve, e, DLC1 DLC1 bracke bracket, t, grou ground nd strap and cable with the 4 nuts. Torque: 14.5 N·m (145 kgf·cm, 10 ft·lbf) CONNECT DLC1 CONN CONNEC ECT T AC ACTU TUA ATOR VAC ACUU UUM M HOSE HOSE

B06468

Seal Packing

Seal Packing

(d)

Rubber S05052

2. 3.

AuthorĂ:

DateĂ:

1551

SF–53 SFI (1MZ–FE) – EFI MAIN RELAY

EFI MAIN M AIN RELA RE LAY Y

SF088–03

INSPECTION 1. 2.

REMOVE RELAY BOX COVER REMO RE MOVE VE EFI EFI MAI MAIN N REL RELA AY (Ma (Mark rkin ing: g: EFI) EFI)

EFI Main Relay

S05392

Continuity Ohmmeter

Ohmmeter

2

1

5

3

3. (a)

INSP INSPEC ECT T EFI EFI MA MAIN IN RE RELA LAY Y CON CONTI TINU NUIT ITY Y Using Using an ohm ohmmet meter er,, check check that that th there ere is is conti continui nuity ty bebetween terminals 1 and 2. If there is no continuity, replace the relay. (b) Che Check ck that that ther there e is no contin continuit uity y be betwe tween en term termina inals ls 3 and and 5. If there is continuity, replace the relay.

No Continuity

S04970

2

Ohmmeter

1 5

3

4. (a) (b)

INSP INSPEC ECT T EFI EFI MA MAIN IN RE RELA LAY Y OPE OPERA RATI TION ON Apply Apply batt battery ery positi positive ve volt voltage age across across termin terminals als 1 an and d 2. Using Using an ohm ohmmet meter er,, check check that that th there ere is is conti continui nuity ty bebetween terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EF EFI MA MAIN RELAY 6. REIN EINSTALL RELAY LAY BOX COVER OVER

Battery Continuity S04969

AuthorĂ:

DateĂ:

1552

SF–54 SFI (1MZ–FE) – CIRCUIT OPENING RELAY

Circuit Opening Relay

CIRCUIT OPENING RELAY

SF089–03

INSPECTION 1. 2.

REMOVE RELAY BOX COVER REMOV EMOVE E CIR CIRCU CUIT IT OPEN PENING ING REL RELA AY (Marking: CIR OPN)

S05389

3. (a)

Continuity Ohmmeter

Ohmmeter

2

1

5

3

INSP INSPEC ECT T CIR CIRCU CUIT IT OPEN OPENIN ING G REL RELA AY CONT CONTIN INUI UITY TY Using Using an ohm ohmmet meter er,, check check that that th there ere is is conti continui nuity ty bebetween terminals 1 and 2. If there is no continuity, replace the relay. (b) Che Check ck that that ther there e is no contin continuit uity y be betwe tween en term termina inals ls 3 and and 5. If there is continuity, replace the relay.

No Continuity

S04970

2

Ohmmeter

1 5

3

4. (a) (b)

INSP INSPEC ECT T CIR CIRCU CUIT IT OPEN OPENIN ING G REL RELA AY OPE OPERA RATI TION ON Apply Apply batt battery ery positi positive ve volt voltage age across across termin terminals als 1 an and d 2. Using Using an ohm ohmmet meter er,, check check that that th there ere is is conti continui nuity ty bebetween terminals 3 and 5. If there is no continuity, replace the relay. 5. REIN RE INST STAL ALL LC CIR IRCU CUIT IT OPEN OPENIN ING GR REL ELA AY 6. REIN EINSTALL RELAY LAY BOX COVER OVER

Battery Continuity S04969

AuthorĂ:

DateĂ:

1553

SF–55 SFI (1MZ–FE) – VSV FOR EXHAUST GAS RECIRCULATION (EGR)

VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF08A–03

COMPONENTS

Vacuum Hose

V–Bank Cover

VSV for EGR

Emission Control Valve Set High–Tension Cord Cover VSV Connector for EVAP VSV Connector for EGR


S04762

AuthorĂ:

DateĂ:

1554

SF–56 SFI (1MZ–FE) – VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF08B–03

INSPECTION 1. 2. (a) (b) (b)

Ohmmeter

REMO REMOVE VE V–BA V–BANK NK COVE COVER, R, HIGH HIGH–T –TEN ENSI SION ON CORD CORD COVER AND EMISSION CONTROL VALVE ALVE SET REMOVE VSV Disco Disconne nnect ct the the 3 vacu vacuum um hose hoses s from from the the VSV. VSV. Remo Re move ve the the scr screw ew and and VSV VSV..

3. INSPECT VS VSV FO FOR OP OPEN CI CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 27 – 33 Ω at 20 C (68 F) If there is no continuity, replace the VSV.

Continuity

°

°

S04514

4. INSPECT VSV FOR GROUND Using an ohmmeter, ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV.

Ohmmeter

No Continuity S04513

5. (a) (a)

Air

INSPECT VS VSV OP OPERATION Chec Ch eck k th that at air air flow flows s from from port port E to por portt G.

E G

S04515

Air

Battery S04512

(b) Apply Apply batt battery ery positi positive ve volt voltage age across across the termin terminals als.. (c) (c) Ch Chec eck k that that air air flo flows ws fro from m po port rt E to to port port F. F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) (a) Inst Instal alll the the VSV VSV wit with h the the scr screw ew.. (b) (b) Co Conn nnec ectt the the 3 vac vacuu uum m hose hoses s to the the VSV VSV.. 7. REIN REINST STAL ALL L EMI EMISS SSIO ION N CONT CONTRO ROL L VAL VALVE VE SET SET 8. REIN REINS STALL ALL HIGH HIGH– –TENS TENSIO ION N CORD CORD CO COVE VER R 9. REINSTALL V– V–BANK CO COVER

AuthorĂ:

DateĂ:

1555

SF–57 ( EVAP) SFI (1MZ–FE) – VSV FOR EVAPORATIVE EMISSION (EVAP)

VSV FOR EVAPORATIVE EMISSION (EVAP) SF08C–03

COMPONENTS

V–Bank Cover

EVAP Hose

VSV for EVAP

Emission Control Valve Set High–Tension Cord Cover VSV Connector for EVAP EVAP VSV for ACIS


VSV Connector for EGR

S04761

AuthorĂ:

DateĂ:

1556

SF–58 SFI (1MZ–FE) – VSV FOR EVAPORATIVE EMISSION (EVAP) SF08D–03


Ohmmeter

REMO REMOVE VE V–BA V–BANK NK COVE COVER, R, HIGH HIGH–T –TEN ENSI SION ON CORD CORD COVER AND EMISSION CONTROL VALVE ALVE SET REMOVE VSV Disco Disconne nnect ct the the 2 EV EVAP hoses hoses from from the the VSV. VSV. Remo Re move ve the the scr screw ew and and VSV VSV..

3. INSPECT VS VSV FO FOR OP OPEN CI CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 27 – 33 Ω at 20 C (68 F) If there is no continuity, replace the VSV. °

°

Continuity S04522

Ohmmeter


No Continuity

S04521

5. (a)

Air

F

INSPECT VS VSV OP OPERATION Check Ch eck that that a air ir flow flows s with with diffi difficul culty ty from from port port E to to port port F. F.

E

P18857

Air

E F

Battery S04520

(b) Apply Apply batt battery ery positi positive ve volt voltage age across across the termin terminals als.. (c) (c) Ch Chec eck k that that air air flo flows ws fro from m po port rt E to to port port F. F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) (a) Inst Instal alll the the VSV VSV wit with h the the scr screw ew.. (b) (b) Co Conn nnec ectt the the 2 EV EVAP hose hoses s to the the VSV VSV.. 7. REIN REINST STAL ALL L EMI EMISS SSIO ION N CONT CONTRO ROL L VAL VALVE VE SET SET 8. REIN REINS STALL ALL HIGH HIGH– –TENS TENSIO ION N CORD CORD CO COVE VER R 9. REINSTALL V– V–BANK CO COVER

AuthorĂ:

DateĂ:

1557

SFI (1MZ–FE) – VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS)

SF–59

VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF08E–03

COMPONENTS

Emission Control Valve Set High–Tension Cord Cover

VSV Connector for EVAP VSV Connector for EGR

VSV Connector for ACIS Vacuum Hose

VSV for ACIS

S04760

AuthorĂ:

DateĂ:

1558

SF–60

SFI (1MZ–FE) – VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF08F–04


Ohmmeter

REMO REMOVE VE V–BA V–BANK NK COVE COVER, R, HIGH HIGH–T –TEN ENSI SION ON CORD CORD COVER AND EMISSION CONTROL VALVE ALVE SET REMOVE VSV Disco Disconne nnect ct the the 2 vacu vacuum um hose hoses s from from the the VSV. VSV. Remo Re move ve the the scr screw ew and and VSV VSV..

3. INSPECT VS VSV FO FOR OP OPEN CI CIRCUIT Using an ohmmeter, check that there is continuity between each terminals. Resistance: 33 – 39 Ω at 20 C (68 F) If there is no continuity, replace the VSV.

Continuity

°

°

S04525

Ohmmeter


No Continuity

S04524

5. (a)

Air

INSPECT VS VSV OP OPERATION Check Ch eck tha thatt air air flows flows from from port port E to the filter filter..

E Filter FI6393

Air

E F Battery S04523

(b) Apply Apply batt battery ery positi positive ve volt voltage age across across the termin terminals als.. (c) (c) Ch Chec eck k that that air air flo flows ws fro from m po port rt E to to port port F. F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) (a) Inst Instal alll the the VSV VSV wit with h the the scr screw ew.. (b) (b) Co Conn nnec ectt the the 2 vac vacuu uum m to to the the VSV VSV. 7. REIN REINST STAL ALL L EMI EMISS SSIO ION N CONT CONTRO ROL L VAL VALVE VE SET SET 8. REIN REINS STALL ALL HIGH HIGH– –TENS TENSIO ION N CORD CORD CO COVE VER R 9. REINSTALL V– V–BANK CO COVER

AuthorĂ:

DateĂ:

1559

SF–61 SFI (1MZ–FE) – VSV FOR VAPOR PRESSURE SENSOR

VSV FOR VAPOR PRESSURE SENSOR SF08G–03

COMPONENTS

VSV for Vapor Pressure Sensor Connector

VSV for Vapor Pressure Sensor

Vacuum Hose

Charcoal Canister

B06550

AuthorĂ:

DateĂ:

1560

SF–62 SFI (1MZ–FE) – VSV FOR VAPOR PRESSURE SENSOR SF08H–03

INSPECTION 1.

REMOVE VSV


Ohmmeter Continuity

°

°

B01273



B00798

4. (a) (a)

Air

INSPECT VS VSV OP OPERATION Chec Ch eck k tha thatt air air flow flows s fro from m por ports ts E to to G. G.

E G

B00799

(b) Apply Apply batt battery ery positi positive ve volt voltage age across across the termin terminals als.. (c) (c) Ch Chec eck k th that at air air flow flows s from from port ports s E to to F F.. If operation is not as specified, replace the VSV. 5. REINSTALL VSV

Air

E

F

Battery

B00800

AuthorĂ:

DateĂ:

1561

SF–63 SFI (1MZ–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR

ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF08I–03

INSPECTION

19 mm Deep Socket Wrench

ECT Switch

Gasket

30 20 10 Ω

DRAIN ENGINE COOLANT

2. (a) (a) (b)

REMOVE EC ECT SE SENSOR Disc Discon onne nect ct the the ECT ECT sens sensor or con conne nect ctor or.. Using Using a 19 mm mm deep deep socket socket wrench wrench,, remo remove ve the ECT sensor and gasket.

S04759

Ohmmeter


1.

5 3 2

Acceptable

3. 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. 4. REINSTALL ECT SENSOR (a) (a) Inst Instal alll a new new gask gasket et to to the the ECT ECT sens sensor or.. (b) Using Using a 19 mm mm de deep ep sock socket, et, instal installl th the e ECT ECT senso sensorr. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (c) (c) Conn Connec ectt the the ECT ECT sen senso sorr con conne nect ctor or.. 5. REFILL ILL WI WITH EN ENGINE CO COOLANT

1 0.5 0.3 0.2 0.1 –20

0

20 40 60 80 100

(–4) (32) (68) (104) (140) (176) (212) S01196 S01699


Z17274

AuthorĂ:

DateĂ:

1562

SF–64 SFI (1MZ–FE) – VAPOR PRESSURE SENSOR

VAPOR PRESSURE SENSOR SF0Z9–01

COMPONENTS



Vacuum hose

Charcoal Canister

B06554

AuthorĂ:

DateĂ:

1563

SF–62 SFI (1MZ–FE) – VSV FOR VAPOR PRESSURE SENSOR SF08H–03

INSPECTION 1.

REMOVE VSV


Ohmmeter Continuity

°

°

B01273



B00798

4. (a) (a)

Air

INSPECT VS VSV OP OPERATION Chec Ch eck k tha thatt air air flow flows s fro from m por ports ts E to to G. G.

E G

B00799

(b) Apply Apply batt battery ery positi positive ve volt voltage age across across the termin terminals als.. (c) (c) Ch Chec eck k th that at air air flow flows s from from port ports s E to to F F.. If operation is not as specified, replace the VSV. 5. REINSTALL VSV

Air

E

F

Battery

B00800

AuthorĂ:

DateĂ:

1561

SF–63 SFI (1MZ–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR

ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF08I–03

INSPECTION

19 mm Deep Socket Wrench

ECT Switch

Gasket

30 20 10 Ω

DRAIN ENGINE COOLANT

2. (a) (a) (b)

REMOVE EC ECT SE SENSOR Disc Discon onne nect ct the the ECT ECT sens sensor or con conne nect ctor or.. Using Using a 19 mm mm deep deep socket socket wrench wrench,, remo remove ve the ECT sensor and gasket.

S04759

Ohmmeter


1.

5 3 2

Acceptable

3. 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. 4. REINSTALL ECT SENSOR (a) (a) Inst Instal alll a new new gask gasket et to to the the ECT ECT sens sensor or.. (b) Using Using a 19 mm mm de deep ep sock socket, et, instal installl th the e ECT ECT senso sensorr. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (c) (c) Conn Connec ectt the the ECT ECT sen senso sorr con conne nect ctor or.. 5. REFILL ILL WI WITH EN ENGINE CO COOLANT

1 0.5 0.3 0.2 0.1 –20

0

20 40 60 80 100

(–4) (32) (68) (104) (140) (176) (212) S01196 S01699


Z17274

AuthorĂ:

DateĂ:

1562

SF–64 SFI (1MZ–FE) – VAPOR PRESSURE SENSOR

VAPOR PRESSURE SENSOR SF0Z9–01

COMPONENTS



Vacuum hose

Charcoal Canister

B06554

AuthorĂ:

DateĂ:

1563

SF–65 SFI (1MZ–FE) – VAPOR PRESSURE SENSOR SF08J–04

Voltmeter

INSPECTION 1. (a) (b) (b) (c)

Disconnect VC E2 B00801

(d) (d) (e)

2.

Type A

(a) (a) (b) (c) Air Vacuum

Disconnect

Type B Disconnect

Air Vacuum

(d) (d) (e)

INSPE INSPECT CT POWE POWER R SOUR SOURCE CE VOL VOLTAGE AGE OF OF VAP APOR OR PRESSURE SENSOR Disco Disconne nnect ct the the vapor vapor pressu pressure re sens sensor or conn connect ector or.. Turn urn the the igni igniti tion on swit switch ch ON. ON. Using Using a voltmet voltmeter er,, meas measure ure the voltag voltage e betw between een connec connec-tor terminals VC and E2 of the wiring harness side. Voltage: 4.5 – 5.5 V Turn urn the the igni igniti tion on swit switch ch OFF OFF. Recon Re conne nect ct the the vapor vapor pressu pressure re sens sensor or conn connect ector or..

INSP INSPEC ECT T POWE POWER R OUT OUTPU PUT T OF OF VAP VAPOR OR PRE PRESS SSUR URE E SENSOR Turn urn the the ign ignit itio ion n swi switc tch h ON. ON. Disco Disconne nnect ct the vacuum vacuum hose hose from from the vapor vapor pres pressur sure e sensor. Conne Co nnect ct a volt voltmet meter er to termin terminal als s PTNK PTNK and E2 of the ECM, and measure the output voltage under the following conditions: (1) Apply Apply vacu vacuum um (2.0 (2.0 kPa kPa (15 mmH mmHg, g, 0.5 0.59 9 in.H in.Hg)) g)) to the vapor pressure sensor. Voltage: 1.3 – 2.1 V (2) Re Relea lease se the the vacu vacuum um from from the the vapor vapor pressu pressure re sensensor. Voltage: 3.0 – 3.6 V (3) Apply Apply pre press ssur ure e (1. (1.5 5 kPa kPa (15 (15 g gf/ f/cm cm2, 0.22 psi)) to the vapor pressure sensor. Voltage: 4.2 – 4.8 V Turn urn the the igni igniti tion on swit switch ch OFF OFF. Recon Re conne nect ct the the vacuu vacuum m hose hose to to the the vapor vapor pressu pressure re sensensor.

ECM

PTNK

E2

B06389

AuthorĂ:

DateĂ:

1564

SF–66 SFI (1MZ–FE) – KNOCK SENSOR

KNOCK SENSOR SF08K–03

COMPONENTS Air Intake Chamber Stay 19.5 (200, 14)

V–Bank Cover

12 (120, 19)

39 (400, 19)

PS Pressure Tube

D

Gasket

No.2 EGR Pipe Throttle Position Sensor Connector No.1 Engine Hanger 43 (440, 32)

VSV Connector for EGR Engine Wire

Brake Booster EGR Valve Position Vacuum Hose Sensor Connector Accelerator Cable D Gasket IAC Valve Connector

VSV Connector for EVAP Ground Cable

Throttle Cable Air Cleaner Hose

Ground Starp DLC1 PCV Hose Air Intake Chamber Assembly D Gasket VSV Connector for ACIS Engine Coolant 15 (150, 11) ECT Sender Reservoir Hose Gauge Connector Upper Radiator x9 Hose ECT Sensor Engine Connector Wire Band Grand Strap Connector

Purge Hose EGR Gas Temperature Sensor Connector Water Bypass Hose Vacuum Hose Air Assist Hose Water Bypass Hose D

Retainer

Fuel Inlet Hose Heater Hose Intake Manifold Assembly

15 (150, 11)

Injector Connector Water Outlet D Gasket

D

Gasket

Knock Sensor Connector

High–Tension Cord Set

Knock Sensor 39 (400, 29)


B06390

AuthorĂ:

DateĂ:

1565

SF–67 SFI (1MZ–FE) – KNOCK SENSOR SF08L–03

INSPECTION

Knock Sensor 1 SST

1. 2. 3.

REMOVE AIR CLEANER HOSE REMO RE MOVE VE RH EN ENGI GINE NE MOUN MOUNTI TING NG STA STAY REMO RE MOVE VE INT INTAK AKE E MAN MANIF IFOL OLD D ASS ASSEM EMBL BLY Y AND AND WATER OUTLET (Seepage EM–32)

4. (a) (b) (b)

REMOVE KNOCK SENSORS Disco Disconne nnect ct the knock knock sensor sensor conne connecto ctorr. Usin Using g SST SST, remo remove ve the the kno knock ck sen senso sorr. SST 09817–1601 1

Knock Sensor 2 P20115

Ohmmeter

No Continuity

P01630

5. INSPECT K KN NOCK SE SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 6. REINSTALL KN KNOCK SE SENSORS (a) Using Using SST, SST, inst instal alll the the knock knock sensor sensor.. SST 09817–1601 1 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) (b) Co Conn nnec ectt the the knoc knock k sens sensor or con conne nect ctor or.. 7. REIN RE INST STAL ALL L WA WATER TER OUT OUTLE LET T AND AND INT INTAK AKE E MANIFOLD ASSEMBLY (See page EM–57) 8. REIN RE INST STAL ALL LR RH H ENG ENGIN INE EM MOU OUNT NTIN ING G ST STAY 9. REIN EINSTALL AIR AIR CLEA LEANE NER R HOSE OSE

AuthorĂ:

DateĂ:

1566

SF–68 SFI (1MZ–FE) – AIR–FUEL RATIO (A/F) SENSOR (California A/T)

Bank 1 Sensor 1 +B

Ohmmeter HT

AIR–FUEL RATIO (A/F) SENSOR (California A/T) SF08M–06

INSPECTION

INSPECT HEATER RESISTANCE OF A/F SENSORS (Bank 1 sensor 1, Bank 2 Sensor 1) (a) (a) Disc Discon onne nect ct the the A/F A/F sen senso sorr conn connec ecto torr. (b) Using Using an an ohmm ohmmeter eter mea measur sure e the the resista resistance nce bet betwee ween n terterminals +B and HT. Resistance:

Bank 2 Sensor 1

Ohmmeter +B

HT

At 20 C (68 F)

0.8 – 1.4 Ω

At 800 C (1,472 F)

1.8 – 3.2 Ω

°

°

°

°

If the resistance is not as specified, replace the sensor. Torque: 44 N·m (440 kgf·cm, 31 ft·lbf) (c) (c) Reco Reconn nnec ectt the the A/F A/F sen senso sorr con conne nect ctor or..

S05042

AuthorĂ:

DateĂ:

1567

SFI (1MZ–FE) – EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR

SF–69

EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR SF08N–03

COMPONENTS D

Gasket 19.5 (200, 14)

Throttle Body

Throttle Position Sensor Connector

EGR Gas Temperature Sensor

IAC Valve Connector

Accelerator Cable (A/T) Throttle Cable

Water Bypass Hose Air Assist Hose Water Bypass Hose

EGR Gas Temperature Sensor Bracket N·m (kgf·cm, ft·lbf) : Specified torque D

Non–reusable part

EGR Gas Temperature Sensor Connector Air Cleaner Hose

AuthorĂ:

S04740

DateĂ:

1568

SF–70

SFI (1MZ–FE) – EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE TEMPERATURE SENSOR SEN SOR SF08O–04

INSPECTION 1.


2.

REMO RE MOVE VE EGR EGR GAS GAS TEMP TEMPER ERA ATURE TURE SENS SENSOR OR

S04504

3. INSP INSPEC ECT T EGR EGR GAS GAS TEM TEMPE PERA RATU TURE RE SENS SENSOR OR Using an ohmmeter, measure the resistance between the terminals. Resistance: At 50 C (122 F)

64 – 97 kΩ

At 100 C (212 F)

11 – 16 kΩ

At 150 C (302 F)

2 – 4 kΩ

°

Oil

°

°

Ohmmeter

P03193

°

°

°

If the resistance is not as specified, replace the sensor. 4. REIN RE INST STAL ALL L EGR EGR GAS GAS TEMP TEMPER ERA ATURE TURE S SEN ENSO SOR R 5. REIN RE INST STAL ALL L THRO THROTT TTLE LE BOD BODY Y (See (See pag page e SF–4 SF–41) 1)

AuthorĂ:

DateĂ:

1569

SF–71 SFI (1MZ–FE) – HEATED OXYGEN SENSOR (Bank 1,2 Sensor 1)

Bank 1 Sensor 1 +B

Ohmmeter HT

HEATED OXYGEN SENSOR (Bank 1,2 Sensor 1) SF08P–04

INSPECTION

Except California A/T: INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (Bank 1 Sensor 1, Bank 2 Sensor 1) (a) Disco Disconne nnect ct the oxygen oxygen sensor sensor connec connector tor.. (b) Using Using an ohm ohmmet meter er,, measu measure re the the resi resistan stance ce betw between een the terminals +B and HT. Resistance:

Bank 2 Sensor 1

Ohmmeter +B

At 20 C (68 F)

11 – 16 Ω

At 800 C (1,472 F)

23 – 32 Ω

°

HT

°

°

°

If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) (c) Re Reco conn nnec ectt the the oxyg oxygen en sen senso sorr conn connec ecto torr. S05042

AuthorĂ:

DateĂ:

1570

SF–72 SFI (1MZ–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 2)

Ohmmeter

+B

HEATED OXYGEN SENSOR (Bank 1 Sensor 2)

HT

SF08Q–03

INSPECTION

S05163

INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR (Bank 1 Sensor 2) (a) (a) Re Remo move ve the the driv driver er’’s seat seat.. (b) (b) Take ake out out the the flo floor or carp carpet et.. (c) (c) Disc Discon onne nect ct the the ox oxyg ygen en sen senso sorr conn connec ecto torr. (d) Using Using an ohm ohmmet meter er,, measu measure re the the resi resistan stance ce betw between een the terminals +B and HT. Resistance: At 20 C (68 F)

11 – 16 Ω

At 800 C (1,472 F)

23 – 32 Ω

°

°

°

°

If the resistance is not as specified, replace the sensor. (e) Re Recon conne nect ct the oxygen oxygen sensor sensor conne connecto ctorr. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (f) (f) Reinst insta all the the flo floo or ca carpet rpet.. (g) (g) Re Rein inst stal alll the the driv driver er’’s sea seat. t.

AuthorĂ:

DateĂ:

1571

SF–73 SFI (1MZ–FE) – ENGINE CONTROL MODULE (ECM)

ENGINE CONTROL MODULE (ECM) SF08R–03

COMPONENTS

ECM

ECM Connector No.2 Instrument Lower Panel

Under Cover

Front Door Inside Scuff Plate Cowl Side Trim

S05450

AuthorĂ:

DateĂ:

1572

SF–74 SFI (1MZ–FE) – ENGINE CONTROL MODULE (ECM) SF08S–01

INSPECTION 1. 2. 3.

REMOVE ECM INSPECT ECM (See page DI–218 DI–218)) REINSTALL ECM

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DateĂ:

1573

SF–75 SFI (1MZ–FE) – FUEL CUT RPM

FUEL CUT RPM

SF08T–03

INSPECTION

5 mm Hexagon Wrench

1. REMOVE V– V–BANK CO COVER (a) Using Using a 5 mm hexago hexagon n wren wrench, ch, remove remove the 2 cap cap nuts. nuts. (b) Disco Disconne nnect ct the the 2 clips clips,, and and remov remove e the V–bank V–bank cover cover.. 2. WARM UP ENGINE Allow the engine to warm up to normal operating temperature.

Clip

S04528

TOYOTA Hand–Held Hand–H eld Tester Tester

3. (a) (b)

CONN CONNEC ECT T TOYO TOYOT TA HAN HAND– D–HE HELD LD TEST TESTER ER OR OBDI OBDIII SCAN TOOL Conne Co nnect ct the the TOYO TOYOTA TA hand– hand–hel held d teste testerr or OBDII OBDII scan scan tool to the DLC3. Please Please refer refer to to the TOYOT TOYOTA A hand– hand–hel held d tester tester or or OBDII OBDII scan tool operator’s manual for further details.

S05358

California A/T

4. (a) (b) (c)

Sound Scope

INSPECT FUEL CUT OFF PRM Increa Increase se the the engi engine ne spe speed ed tto oa att least least 3,5 3,500 00 rpm. rpm. Use a sound sound scope scope to check check for for injec injector tor oper operati ating ng n nois oise. e. Check Check that that when when the the thro throttl ttle e lever lever is rele release ased, d, inje injecto ctorr opoperation noise stops momentarily and then resumes.

HINT: Measure with the A/C OFF. Fuel return rpm: 1,200 rpm 5. DISC DISCON ONNE NECT CT TOY TOYOT OTA A HAN HAND– D–HE HELD LD TES TESTE TER R OR OR OBDII SCAN TOOL 6. REINSTALL V–BANK COVER HINT: For fixing the V–bank cover, push on the cover until a ”click” is felt.

Except California A/T Sound Scope

B00623

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DateĂ:

1574

SFI

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