COMPONENTS SF-52 ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) Suction Hose. Throttle Body Cover. MAF Meter Wire. Vacuum Hose. PS Air Hose.

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1 SF52 SFI (2UZFE) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) COMPONENTS SF1XM01 Suction Hose MAF Meter Wire Throttle Body Cover PS Air Hose Vacuum Hose PCV Hose Intake Air Connector B

2 SFI (2UZFE) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF53 Engine Wire Engine Wire VSV Connector 18 (185, 13) VSV Connector 18 (185, 13) 18 (185, 13) Injector Connector Fuel Return Hose Throttle Body Connector VSV Connector for EVAP Engine Wire Gasket N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

3 SF54 SFI (2UZFE) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) 7.5 (80, 66 in. lbf) VSV Wire Connector Intake Manifold Assembly VSV for ACIS 7.5 (80, 66 in. lbf) Vacuum Hose N m (kgf cm, ft lbf) : Specified torque Vacuum Hose B

4 SF56 SFI (2UZFE) INSPECTION ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF1XO01 1. INSPECT INTAKE AIR CONTROL VALVE (a) With 39.9 kpa (300 mmhg, 11.8 in.hg) of vacuum applied to the actuator, check that the actuator rod moves. (b) One minute after applying the vacuum in step (a), check that the actuator rod does not return. If the operation is not as specified, replace the intake manifold. B17511 Ohmmeter Continuity 2. INSPECT VSV (a) Using an ohmmeter, check that there is continuity between each terminal. Resistance: 33 to 39 Ω at 20 C (68 F) If there is no continuity, replace the VSV. S04525 Ohmmeter No continuity (b) Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. S04524 Air (c) Check that air flows from port E to the filter. E Filter FI6393 Air (d) Apply battery voltage across the terminals. (e) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. E F Battery S

5 B17510 SFI (2UZFE) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) INSTALLATION 1. INSTALL VSV FOR ACIS (a) Install the VSV to the intake manifold with the bolt. Torque: 7.5 N m (76 kgf cm, 66 in. lbf) (b) Connect the 2 vacuum hoses to the VSV. 2. INSTALL INTAKE MANIFOLD ASSEMBLY (See page EM60 ) 3. INSTALL THROTTLE BODY COVER SF57 SF1XP

6 SFI (2UZFE) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF51 ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) ONVEHICLE INSPECTION INSPECT INTAKE AIR CONTROL VALVE OPERATION (a) Start the engine. SF0PD04 (b) While the engine idling, check that the actuator rod moves. B17508 Disconnect (c) Disconnect the VSV connector, and check that the actuator rod is returned. If the operation is not as specified, inspect the intake air control valve, VSV and ECM. B

7 SFI (2UZFE) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) REMOVAL 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE MANIFOLD ASSEMBLY (See page EM36 ) SF55 SF1XN02 3. REMOVE VSV FOR ACIS (a) Remove the 2 vacuum hoses from the VSV. (b) Remove the bolt and VSV from the intake manifold. B

8 SFI (2UZFE) AIRFUEL RATIO (A/F) SENSOR COMPONENTS AIRFUEL RATIO (A/F) SENSOR SF71 SF1XV02 Bank 2 Sensor 1 Airfuel Ratio Sensor 44 (450, 32) Airfuel Ratio Sensor Connector Bank 1 Sensor 1 Airfuel Ratio Sensor 44 (450, 32) Airfuel Ratio Sensor Connector Engine Under Cover N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

9 SF72 +B HT B17505 SFI (2UZFE) INSPECTION AIRFUEL RATIO (A/F) SENSOR SF1XW02 1. INSPECT HEATER RESISTANCE OF AIR FUEL RATIO SENSOR (a) Disconnect the air fuel ratio sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance 11 to 16 kω 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) Reconnect the air fuel ratio sensor connector. 2. INSPECT OPERATION OF AIR FUEL RATIO SENSOR (See page DI507 ) E1 3. INSPECT AIRFUEL RATIO COMPENSATION SYS TEM (a) Measure the voltage between the terminals of the ECM connectors. Standard: Tester Connection Condition Specified Condition B3 B2 C1 C2 B222 (A1A+) B11 (E1) B230 (A1A) B11 (E1) Ignition switch ON Ignition switch ON 3.3 V 2.9 V B1 A2A+ A1A+ B223 (A2A+) B11 (E1) Ignition switch ON 3.3 V A2A A1A B17512 B231 (A2A) B11 (E1) Ignition switch ON 2.9 V NOTICE: Connect test leads from the back side of the connector. The connectors should not be disconnected from the ECM. HINT: The voltage between the terminals of the ECM is kept constant regardless of the voltage of the A/F sensor. 3657

10 SFI (2UZFE) AIRFUEL RATIO (A/F) SENSOR SF73 DLC3 CAN VIM HandHeld Tester D13872 (b) Connect a handheld tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (c) Turn the ignition switch ON. (d) Select the following menu items : Data List / A/FS B1 S1 and O2S B1 S2. (e) Warm up the A/F sensor by running the engine at 2,500 rpm for approximately 2 minutes. (V) 3.3 Keep Engine Speed Time Lean 14.6 Rich Airfuel Ratio B17513 (f) Keep the engine speed at 2,500 rpm and confirm that the display of the A/FS B1 S1 is as shown in the illustration. HINT: The illustration may slightly differ from the display on the handheld tester. The waveform of the A/F sensor is displayed only on the hanndheldtester. (g) Confirm that the display of the O2S B1 S2 changes between 0 and 1 V with the engine speed at 2,500 rpm. OK: The voltage output oscillates more than 8 times in 10 seconds. CAUTION: Perform the check immediately after warming up the engine. If the voltage variation could not be verified, warm up the heated oxygen sensor again. If it could not be verified even after warming up the sensor again, check the DTC No. (See page DI507 ) 3658

11 SF80 SFI (2UZFE) ACCELERATOR PEDAL POSITION SENSOR ACCELERATOR PEDAL POSITION SENSOR COMPONENTS SF1UM05 Accelerator Pedal Position Sensor Connector Accelerator Pedal Position Sensor 5.0 (51, 44 in. lbf) Accelerator Pedal Assembly N m (kgf cm, ft lbf) : Specified torque B

12 SFI (2UZFE) ACCELERATOR PEDAL POSITION SENSOR INSPECTION INSPECT ACCELERATOR PEDAL POSITION SENSOR (See page DI794 ) If necessary, replace the accelerator pedal assembly. NOTICE: Be care not to give a shock to the accelerator pedal assembly. Be care not to disassemble the accelerator pedal assembly. SF81 SF1UN

13 SFI (2UZFE) A/F SENSOR HEATER RELAY SF59 A/F SENSOR HEATER RELAY INSPECTION 1. REMOVE RELAY BOX COVER SF1XR01 2. REMOVE A/F SENSOR HEATER RELAY (Marking: A/F HTR) Continuity Ohmmeter Ohmmeter 3. INSPECT A/F SENSOR HEATER RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04947 Battery Ohmmeter 5 Continuity S INSPECT A/F SENSOR HEATER RELAY OPERATION (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL A/F SENSOR HEATER RELAY 6. REINSTALL RELAY BOX COVER 3644

14 SF60 SFI (2UZFE) CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE CIRCUIT OPENING RELAY (Marking: C/O) SF1XS01 Continuity Ohmmeter Ohmmeter 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04947 Battery Ohmmeter Continuity S INSPECT CIRCUIT OPENING RELAY OPERATION (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL RELAY BOX COVER 3645

15 SFI (2UZFE) CAMSHAFT TIMING OIL CONTROL VALVE SF47 COMPONENTS SF0P903 Suction Hose MAF Meter Wire Throttle Body Cover PS Air Hose Vacuum Hose PCV Hose Camshaft Oil Control Valve (Bank 2) Intake Air Connector ORing 7.5 (76, 66 in. lbf) Camshaft Oil Control Valve (Bank 1) ORing N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

16 1 2 SFI (2UZFE) CAMSHAFT TIMING OIL CONTROL VALVE SF49 SF0PB02 INSPECTION INSPECT OIL CONTROL VALVE OPERATION Connect the positive lead to terminal 1 of the connector and the negative lead to terminal 2, then check the movement of the valve. When battery positive voltage is applied. Valve moves in direction. B01689 When battery positive voltage is cut off. Valve moves in direction. If operation is not as specified, replace the oil control valve. 3634

17 SF50 SFI (2UZFE) INSTALLATION Installation is in the reverse order of removal. (See page SF48 ) CAMSHAFT TIMING OIL CONTROL VALVE SF1XL

18 SF46 SFI (2UZFE) CAMSHAFT TIMING OIL CONTROL VALVE CAMSHAFT TIMING OIL CONTROL VALVE ONVEHICLE INSPECTION (a) Remove the throttle body cover. (b) Remove the intake air connector. (c) Disconnect the oil control valve connector. SF0P803 Ohmmeter (d) Using an ohmmeter, measure the resistance between the terminals. Resistance: 6.9 to 7.9 Ω at 20 C (68 F) If the resistance is not as specified, replace the valve. (e) Reconnect the oil control valve connector. (f) Reinstall the intake air connector. (g) Reinstall the throttle body cover. B

19 SF48 SFI (2UZFE) CAMSHAFT TIMING OIL CONTROL VALVE REMOVAL 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR SF1XK01 B REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (a) Disconnect the 2 camshaft oil control valve connectors. (b) Remove the bolt, camshaft oil control valve and Oring. Torque: 7.5 N m (76 kgf cm, 66 in. lbf) (c) Remove the Oring from the each camshaft oil control valve. HINT: At the time of installation, please refer to the following items. Use a new Orings. 3633

20 SF82 SFI (2UZFE) ENGINE CONTROL MODULE (ECM) COMPONENTS ENGINE CONTROL MODULE (ECM) SF0Q014 ECM Connector Heater to Register Duct Lower No.2 Finish Panel ECM and Bracket Assembly ECM ECM Bracket ECM Bracket Glove Compartment Door B

21 SFI (2UZFE) ENGINE CONTROL MODULE (ECM) INSPECTION 1. DISCONNECT CABLE FROM NEGATIVE () BATTERY TERMINAL 2. REMOVE REMOVE GLOVE COMPARTMENT (a) Remove the 2 screws and glove compartment door. (b) Remove the 3 screws and lower No.2 finish panel. 3. REMOVE HEATER TO REGISTER DUCT 4. REMOVE ECM (a) Disconnect the 5 connectors. (b) Remove the 2 bolts and ECM. 5. INSPECT ECM (See page DI453 ) 6. REINSTALL ECM (a) Install the ECM with the 2 bolts. (b) Connect the 5 connectors. 7. INSTALL HEATER TO REGISTER DUCT 8. INSTALL GLOVE COMPARTMENT (a) Install the lower No.2 finish panel with 3 screws. (b) Install the glove compartment door with the 2 screws. 9. CONNECT CABLE TO NEGATIVE () BATTERY TERMINAL SF83 SF0Q

22 SF66 SFI (2UZFE) ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR COMPONENTS SF0PN13 Suction Hose Throttle Body Cover MAF Meter Wire PS Air Hose Vacuum Hose PCV Hose Intake Air Connector ECT Sensor Connector ECT Sensor 20 (204, 15) Gasket N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

23 SFI (2UZFE) ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF67 SF0PO20 INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MAN IFOLDS Remove the nut and 3 bolts, and disconnect the throttle body from the intake manifold. 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Remove the ECT sensor and gasket. B02308 Resistance kω S01196 S01699 Ohmmeter Acceptable (4) (32) (68) (104)(140) (176) (212) Temperature C ( F) Z INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket and the ECT sensor. Torque: 19.6 N m (200 kgf cm, 14 ft lbf) (b) Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MAN IFOLDS Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 20 N m (204 kgf cm, 15 ft lbf) 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT (See page CO2 ) 11. REINSTALL THROTTLE BODY COVER 3652

24 SF58 SFI (2UZFE) EFI MAIN RELAY EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) SF1XQ01 Continuity Ohmmeter Ohmmeter 3. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04947 Battery Ohmmeter 5 Continuity S INSPECT EFI MAIN RELAY OPERATION (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER 3643

25 SF84 SFI (2UZFE) FUEL CUT RPM FUEL CUT RPM INSPECTION 1. WARM UP ENGINE SF0Q216 Allow the engine to warm up to normal operating temperature. DLC3 CAN VIM HandHeld Tester D CONNECT HANDHELD TESTER (a) Connect a handheld tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (b) Please refer to the handheld tester operator s manual for further details. Sound Scope B INSPECT FUEL CUTOFF RPM OPERATION (a) Increase the engine speed to at least 2,500 rpm. (b) Check for injector operating noise. (c) Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: The vehicle should be stopped. Measure with the A/C OFF. Fuel return speed: 1,400 rpm (d) Disconnect the handheld tester and CAN VIM from the DLC

26 SFI (2UZFE) FUEL PRESSURE REGULATOR COMPONENTS FUEL PRESSURE REGULATOR SF21 SF0XZ13 Vacuum Hose Fuel Return Hose 7.5 (80, 66 in. lbf) Fuel Pressure Regulator ORing N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

27 Turn Install B17760 SFI (2UZFE) FUEL PRESSURE REGULATOR INSTALLATION SF23 SF0Y INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new Oring, and install it to the pressure regulator. (b) While turning the pressure regulator left and right, install it to the delivery pipe. (c) Install the pressure regulator with the 2 bolts. Torque: 7.5 N m (76 kgf cm, 66 in. lbf) Fuel Return Hose (d) Connect the vacuum hose to intake air resonator. (e) Connect the fuel return hose to the pressure regulator. 2. CHECK FOR FUEL LEAKS (See page SF1 ) Vacuum Hose B

28 SF22 Fuel Return Hose Vacuum Hose SFI (2UZFE) REMOVAL FUEL PRESSURE REGULATOR SF0Y010 REMOVE FUEL PRESSURE REGULATOR (a) Disconnect the vacuum hose from intake air resonator. (b) Disconnect the fuel return hose from the pressure regulator. CAUTION: Put a shop towel under the pressure regulator. B07053 (c) (d) Remove the 2 bolts, and pull out the pressure regulator. Remove the Oring from the pressure regulator. B

29 SFI (2UZFE) FUEL PUMP RELAY FUEL PUMP RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE FUEL PUMP RELAY (Marking: F/P) SF61 SF1XT01 Continuity Ohmmeter Ohmmeter 3. INSPECT FUEL PUMP RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 3 No Continuity B Ohmmeter INSPECT FUEL PUMP RELAY OPERATION (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. 5. REINSTALL FUEL PUMP RELAY 6. REINSTALL RELAY BOX COVER Battery 3 Continuity B

30 SF62 SFI (2UZFE) FUEL PUMP RESISTOR FUEL PUMP RESISTOR COMPONENTS SF (82, 71 in. lbf) Fuel Pump Resistor N m (kgf cm, ft lbf) : Specified torque B

31 Ohmmeter B17501 SFI (2UZFE) FUEL PUMP RESISTOR SF63 SF13905 INSPECTION 1. REMOVE FUEL PUMP RESISTOR 2. INSPECT FUEL PUMP RESISTOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.70 to 0.76 Ω at 20 C (68 F) If the resistance is not as specified, replace the resistor. 3. REINSTALL FUEL PUMP RESISTOR Torque: 8.0 N m (82 kgf cm,71 in. lbf) 3648

32 FUEL TANK AND LINE COMPONENTS SFI (2UZFE) FUEL TANK AND LINE CAUTION: Always use new gaskets when replacing the fuel tank or component parts. Apply the proper torque to all parts tightened SF33 SF0OZ18 Fuel Return Tube Fuel Pump Gauge Retainer Fuel Pump and Sender Gauge Assembly Charcoal Canister Assembly Fuel Main Tube Gasket Fuel Tank Cap VENT Tube Fuel Pump Suction Support Speed Sensor Wire Fuel Inlet Pipe Shield Fuel Tank Fuel Inlet Pipe Fuel Inlet Hose Fuel Tank Protector Clip Fuel Tank Band Pin Fuel Tank Band Pin No.2 Fuel Tank Band No.1 Fuel Tank Band Clip 62 (632, 45) 62 (632, 45) N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

33 SF36 Crack Leakage Deformation 2 7 mm ( in.) Pipe BO0919 Hose SFI (2UZFE) FUEL TANK AND LINE INSPECTION SF0P015 INSPECT FUEL TANK AND LINE (a) Check the fuel lines for cracks or leakage, and all connections for deformation. (b) Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. (c) Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. (d) Check the filler neck for damage or fuel leakage. (e) Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Clip 0 3 mm ( in.) FU0041 Hose Clamp Area Fuel Inlet Hose Clamp 0 3 mm ( in.) B

34 SFI (2UZFE) FUEL TANK AND LINE INSTALLATION SF37 SF1Y INSTALL FUEL PUMP ASSEMBLY (See page SF19 ) 2. INSTALL FUEL TANK ASSEMBLY (a) Set up the fuel tank on the transmission jack. (b) Operate the transmission jack and install the fuel tank. (c) Install the 2 fuel tank bands with the 2 bolts. Torque: 62 N m (632 kgf cm, 45 ft lbf) B17591 (d) Install the fuel pipe bracket to the body with the 2 nuts. Torque: 20 N m (204 kgf cm, 15 ft lbf) 3. CONNECT FUEL PUMP CONNECTOR B CONNECT FUEL MAIN TUBE AND RETURN TUBE (See page SF1 ) B CONNECT SPEED SENSOR WIRE Connect the speed sensor wire to the fuel tank with the nut. B INSTALL CHARCOAL CANISTER ASSEMBLY (a) Connect the pump module connector, vent hose and purge line hose to the charcoal canister. (b) Install the charcoal canister assembly with the 4 bolts. Torque:14.7 N m (150 kgf cm, 11 ft lbf) B

35 SF38 SFI (2UZFE) FUEL TANK AND LINE 7. INSTALL FUEL INLET PIPE SHIELD (a) Install the fuel inlet pipe shield with the 4 bolts. (b) Install the fuel tank cap. 8. CHECK FOR FUEL LEAKS 9. INSTALL SPARE TIRE B

36 SF34 SFI (2UZFE) FUEL TANK AND LINE REMOVAL 1. PREVENT GASOLINE FROM SPILLING OUT (See page SF1 ) 2. REMOVE FUEL TANK CAP 3. REMOVE FUEL INLET PIPE SHIELD Remove the 4 bolts and fuel inlet pipe shield. SF1Y201 B REMOVE CHARCOAL CANISTER ASSEMBLY (a) Remove the 4 bolts and charcoal canister assembly. (b) Disconnect the pump module connector, vent hose and purge line hose from the charcoal canister. B DISCONNECT SPEED SENSOR WIRE Remove the nut and disconnect the speed sensor wire from the fuel tank. B DISCONNECT FUEL MAIN TUBE AND RETURN TUBE (See page SF1 ) B REMOVE FUEL TANK ASSEMBLY (a) Set up a transmission jack under the fuel tank. (b) Remove the 2 nuts and disconnect the fuel pipe bracket from the body. B

37 SFI (2UZFE) FUEL TANK AND LINE SF35 (c) Remove the 2 bolts and disconnect the 2 fuel tank bands from the fuel tank. (d) Operate the transmission jack and remove the fuel tank. 8. REMOVE FUEL PUMP ASSEMBLY (See page SF1 1) B

38 SFI (2UZFE) FUEL PUMP SF9 COMPONENTS SF12Z06 Fuel Return Tube Fuel Pump Gauge Retainer Fuel Pump and Sender Gauge Assembly Charcoal Canister Assembly Fuel Main Tube Gasket Fuel Tank Cap VENT Tube Fuel Pump Suction Support Speed Sensor Wire Fuel Inlet Pipe Shield Fuel Tank Fuel Inlet Pipe Fuel Inlet Hose Fuel Tank Protector Clip Fuel Tank Band Pin Fuel Tank Band Pin No.2 Fuel Tank Band No.1 Fuel Tank Band Clip 62 (632, 45) 62 (632, 45) N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

39 SF10 SFI (2UZFE) FUEL PUMP Fuel Suction Plate No.1 w/ Fuel Filter Fuel Pump Harness Fuel Sender Gauge ORing Spring Fuel Suction Plate No.2 ERing Fuel Pump Fuel Suction Filter Fuel Subtank Nonreusable part B

40 SF12 SFI (2UZFE) FUEL PUMP DISASSEMBLY SF1XE02 1. REMOVE FUEL SENDER GAGE (a) Disconnect the sender gage connector from the fuel suction plate No.1. B17539 Unlock (b) Unlock the fuel sender gage and slide the remove. (a) Slide B REMOVE FUEL SUBTANK (a) Disconnect the fuel pump harness connector from the fuel suction plate No.1. B17543 (b) Disconnect the suction filter hose from the fuel subtank. B17544 (c) Disconnect the 2 tubes from the tube clamps. B

41 SFI (2UZFE) FUEL PUMP SF13 (d) Using a screwdriver with the tip wrapped in tape, disconnect the 3 snapclaws from the fuel suction support No.2. NOTICE: Do not damage the fuel suction plate No.2 or fuel subtank. (e) Disconnect the fuel suction plate No.1 with the fuel filter assembly from the fuel subtank. B REMOVE FUEL FILTER WITH FUEL PUMP (a) Using a screwdriver with the tip wrapped in tape, disconnect the 2 snapclaws from the fuel suction support. NOTICE: Do not damage the fuel filter assembly or fuel suction support. (b) Remove the fuel filter assembly with fuel pump from the fuel suction support. B REMOVE FUEL PUMP (a) Using a screwdriver with the tip wrapped in tape, disconnect the 5 snapclaws from the suction filter. NOTICE: Do not damage the fuel filter assembly or suction filter. (b) Remove the fuel suction filter with fuel pump from the fuel filter. B17546 (c) Disconnect the fuel pump harness from the fuel pump. B17609 (d) Remove the Oring from the fuel filter or fuel pump. B

42 SF14 SFI (2UZFE) FUEL PUMP 5. REMOVE FUEL SUCTION PLATE NO.2 (a) Using a screwdriver, remove the 2 Erings from the suction plate No.2. (b) Remove the suction plate No.2 and 2 springs from the fuel suction plate No.1. B

43 Ohmmeter SFI (2UZFE) FUEL PUMP SF15 SF13104 INSPECTION 1. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: Ω at 20 C (68 F) If the resistance is not as specified, replace the fuel pump. B Battery B INSPECT FUEL PUMP OPERATION (a) Connect the lead wire to the fuel pump. (b) Connect the positive (+) lead from the battery to terminal 1 of the connector, and the negative () lead to terminal 2. Check that the fuel pump operates. NOTICE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. Always do switching at the battery side. If operation is not as specified, replace the fuel pump and/or read wire. (c) Disconnect the lead wire to the fuel pump. 3600

44 Key Keyway B17551 SFI (2UZFE) FUEL PUMP INSTALLATION SF19 SF1XG02 1. INSTALL FUEL PUMP ASSEMBLY (a) Install a new gasket to the fuel tank. (b) Install the fuel pump assembly to the fuel tank. NOTICE: Be careful not to bend the arm of the fuel sender gage. (c) Align the keyway of the fuel suction tube support with the key of the fuel suction plate No.1. S Mark (d) (e) Apply MP grease to the entire interior surface of the fuel pump gage retainer. Align the triangle mark on new fuel pump gage retainer with the S mark on the fuel tank while pushing down the fuel suction tube, attach the fuel pump gage retainer. Triangle Mark B17552 SST Rib Triangle Mark MAX. Mark (f) Rotate the fuel pump gage retainer by hand, then tighten it one complete turn and half using SST. Triangle mark on the fuel pump gage retainer must be positioned between A and MAX. indications on the fuel tank. SST ( , , ) NOTICE: Do not use other tools in this operation. Damage to the fuel pump gage retainer and the fuel tank may result. HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST. A Mark B CONNECT FUEL SUCTION TUBE Connect the fuel pump tube and return tube to the fuel tank with the tube joint clips. Tube Joint Clip B

45 SF20 SFI (2UZFE) FUEL PUMP NOTICE: Check that there are no scratches or foreign objects on the connecting part. Check that the fuel tube joint is inserted securely. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube join clip, check that the fuel tube joint has not been pulled off. 3. CHECK FOR FUEL LEAKS 4. INSTALL FUEL TANK ASSEMBLY (See page SF37 ) 3605

46 DLC3 CAN VIM HandHeld Tester D13872 SFI (2UZFE) FUEL PUMP FUEL PUMP ONVEHICLE INSPECTION SF7 SF12Y06 1. CHECK FUEL PUMP OPERATION (a) Connect a handheld tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (b) Turn the ignition switch ON, and push the handheld tester main switch ON. NOTICE: Do not start the engine. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (d) Please refer to the handheld tester operator s manual for further details. Up Screw Pulsation Damper B16497 (e) Check that the pulsation damper screw rises up when the fuel pump operates. If operation is not as specified, check the fusible link, fuses, EFI main relay, fuel pump, ECM and wiring connections. (f) Turn the ignition switch OFF. (g) Disconnect the handheld tester and CAN VIM from the DLC3. 2. CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative () terminal cable from the battery. (c) Remove the front fuel pipe from the LH delivery pipe (see page SF27 ). SST (Gauge) SST (Union) SST (Adaptor) Front Fuel Pipe Gasket (d) (e) (f) (g) Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and SST (adaptor). SST ( , ) Torque: 39 N m (400 kgf cm, 29 ft lbf) Wipe off any splattered gasoline. Reconnect the negative () terminal cable to the battery. Connect a handheld tester to the DLC3. (See step 1 in check fuel pump operation (a) to (e)) B

47 SF8 SFI (2UZFE) FUEL PUMP (h) Measure the fuel pressure. Fuel pressure: kpa ( kgf/cm 2, psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. (i) Disconnect the handheld tester from the DLC3. (j) Start the engine. (k) Measure the fuel pressure at idle. Fuel pressure: kpa ( kgf/cm 2, psi) (l) Stop the engine. (m) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kpa (1.5 kgf/cm 2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (n) After checking fuel pressure, disconnect the negative () terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST (o) Reinstall the front fuel pipe to the LH delivery pipe. (see page SF31 ) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMI NAL 4. INSPECT FOR FUEL LEAKS (See page SF1 ) 3593

48 SF16 SFI (2UZFE) FUEL PUMP REASSEMBLY SF1XF02 1. REMOVE FUEL SUCTION PLATE NO.2 (a) Install the 2 springs and suction plate No.2 to the suction plate No.1. (b) Using a needlenose pliers, install the 2 new Erings to the suction plate No.2. B INSTALL FUEL PUMP (a) Apply a light coat of gasoline or spindle oil to a new O ring, and install it to the fuel pump. B17548 (b) Connect the fuel pump harness connector to the fuel pump. B17609 (c) Install the fuel pump with the suction filter to the fuel fuel filter. B INSTALL FUEL FILTER Install the fuel filter to the fuel subtank. B

49 SFI (2UZFE) FUEL PUMP SF17 4. INSTALL FUEL SUBTANK (a) Connect the fuel suction plate No.2 to the fuel subtank with the 3 snapclaws engaged. B17541 (b) Connect the 2 tubes to the tube clamps. B17608 (c) Connect the suction filter hose to the fuel subtank. B17544 (d) Connect the fuel pump harness connector to the fuel suction plate No.1. B INSTALL FUEL SENDER GAGE (a) Install the fuel sender gage to the fuel suction support. B

50 SF18 SFI (2UZFE) FUEL PUMP (b) Connect the sender gage connector to the fuel suction plate No.1. B

51 SFI (2UZFE) FUEL PUMP REMOVAL SF1 1 SF REMOVE FUEL TANK ASSEMBLY (See page SF34 ) 2. DISCONNECT FUEL SUCTION TUBE Remove the 2 tube clips, and pull out the 2 fuel tubes. Tube Joint Clip B17536 Nylon Tube ORing Fuel Tube Joint Tube Joint Clip B17537 NOTICE: Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary. Be careful of mud. The connector s Oring, which seals the pipe and connector, becomes contaminated easily. Do not use any tool in this operation. Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag. When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully. SST Rib B REMOVE FUEL PUMP ASSEMBLY (a) Using SST, loosen the fuel pump gage retainer. SST ( , , ) HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST. (b) Remove the fuel pump gage retainer. (c) Remove the fuel suction tube. NOTICE: Be careful not to bend the arm of the fuel sender gage. (d) Remove the gasket from the fuel tank. 3596

52 SF74 SFI (2UZFE) HEATED OXYGEN SENSOR COMPONENTS Heated Oxygen Sensor Connector HEATED OXYGEN SENSOR SF0Y912 Bank 2 Sensor 1 Heated Oxygen Sensor 44 (450, 32) Engine Under Cover Bank 1 Sensor 1 Heated Oxygen Sensor 44 (450, 32) Heated Oxygen Sensor Connector N m (kgf cm, ft lbf) : Specified torque B

53 +B HT B17507 SFI (2UZFE) INSPECTION HEATED OXYGEN SENSOR SF75 SF0YA15 1. INSPECT HEATER RESISTANCE OF HEATED OXY GEN SENSOR (a) Disconnect the oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: 11 to 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) Reconnect the oxygen sensor connector. 2. INSPECT OPERATION OF HEATED OXYGEN SEN SOR (See page DI512 ) 3660

54 SFI (2UZFE) INJECTOR SF25 COMPONENTS SF0OS15 Suction Hose MAF Meter Wire Throttle Body Cover PS Air Hose Vacuum Hose PCV Hose Intake Air Connector B

55 SF26 SFI (2UZFE) INJECTOR Engine Wire Clamp Gasket Gasket Vacuum Hose 39 (400, 29) Front Fuel Pipe 39 (400, 29) Gasket ORing RH Delivery Pipe 7.5 (76, 66 in. lbf) 7.5 (76, 66 in. lbf) Fuel Pressure Regulator 18 (184, 13 ) Fuel Return Hose 21 (214, 15 ) 21 (214, 15 ) LH Delivery Pipe ORing Grommet VSV for EVAP * 33 (340, 24) 39 (400, 29) Fuel Pressure Pulsation Damper Upper Gasket Fuel Main Hose Lower Gasket Injector Insulator Fuel Return Pipe Injector Connector EVAP Hose VSV Connector for EVAP Throttle Body Cover Bracket PCV Hose N m (kgf cm, ft lbf) : Specified torque Nonreusable part * For use with SST B

56 Pressure Regulator SST SST Injector SST SST B07326 SFI (2UZFE) INJECTOR SF29 SF13404 INSPECTION 1. INSPECT INJECTOR INJECTION CAUTION: Keep the injector clean of sparks during the test. (a) Disconnect the fuel inlet hose (fuel tube connector) from the fuel filter. (b) Connect SST (attachment and hose) to the fuel tube. SST ( ) Pressure Regulator SST (Hose) SST (Union) Fuel Return Hose B04988 (c) (d) (e) (f) Remove the pressure regulator from the delivery pipe. Install the Oring to the fuel inlet of the pressure regulator. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST ( ) Torque: 7.5 N m (76 kgf cm, 66 in. lbf) Connect the fuel return hose to the fuel outlet of the pressure regulator. SST (Adaptor) ORing Vinyl Hose SST (Hose) SST (Clamp) B00884 (g) Install the Oring to the injector. (h) Connect SST (adaptor and hose) to the injector, and hold the injector and union with SST (clamp). SST ( , ) (i) Put the injector into the graduated cylinder. CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. DLC3 CAN VIM HandHeld Tester D13872 (j) Connect a handheld tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (k) Connect the battery negative () cable to the battery. (l) Turn the ignition switch ON, and push the handheld tester main switch ON. NOTICE: Do not start the engine. (m) Enter the following menus: DIAGNOSIS / ENHANCED OBDII / ACTIVE TEST / FUEL PUMP / SPD (n) Please refer to the handheld tester operator s manual for further details. 3614

57 SF30 SFI (2UZFE) INJECTOR Connect SST (Wire) (o) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST Volume: 56 to 69 cm 3 (3.4 to 4.2 cu in.) per 15 seconds Difference between each injector: 13 cm 3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector. B00883 A INSPECT LEAKAGE (a) Under the above conditions, disconnect the tester probes of SST (wire) from the battery and check fuel leakage from the injector. SST Fuel drop: 1 drop or less per 12 minutes (b) Turn the ignition switch off. (c) Disconnect the negative () terminal cable from the battery. (d) Remove the SST and fuel tube connector. SST , (e) Disconnect the handheld tester and CAN VIM from the DLC3. (f) Reconnect the fuel inlet pipe to the fuel tube. 3615

58 SFI (2UZFE) INJECTOR SF31 SF13507 INSTALLATION 1. INSTALL INJECTORS AND DELIVERY PIPES NOTICE: Be careful not to drop the injectors when installing the delivery pipes. Do not apply any load to the injector on horizontal direction. (a) (b) Install a new grommet to each injector. Apply a light coat of gasoline to a new Oring and install it to each injector. New Grommet New ORing A01296 Connector Outward Turn Push B04439 Fuel Return Pipe (c) (d) (e) (f) (g) (h) (i) While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 8 injectors. Position the injector connector outward. Place the 8 new insulators on the intake manifold. Place the 2 delivery pipes and injectors assemblies on the lower intake manifold. Temporarily install the 4 nuts. Install the front fuel pipe with the bolt, 4 new gaskets and 2 union bolts. Torque: 39 N m (400 kgf cm, 29 ft lbf) for union bolts 7.5 N m (76 kgf cm, 66 in. lbf) for bolt Install the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Torque: 7.5 N m (76 kgf cm, 66 in. lbf) B17461 Rotate Outward Connector B04438 (j) Check that the injectors rotate smoothly. HINT: If the injectors do not rotate smoothly, the probable cause is incorrect installation of Orings. Replace the Oring of the injector that does not rotate smoothly. (k) Position injector connector outward. (l) Tighten the 4 nuts holding the delivery pipes to the lower intake manifold. Torque: 21 N m (214 kgf cm, 15 ft lbf) 3616

59 SF32 SFI (2UZFE) INJECTOR (m) Connect the 8 injector connectors. Clamp 2. INSTALL ENGINE WIRES (a) Install the 2 wire clamps on the engine wire to the brackets on the RH delivery pipe. (b) Connect the engine wire clamps to the No.1 engine hanger and engine wire bracket. (c) Install the engine wire protector with the 2 bolts. 3. CONNECT PCV HOSE TO PCV VALVE Clamp B07534 (a) Throttle Body Cover Bracket (c) (b) B CONNECT VSV FOR EVAP TO UPPER INTAKE MAN IFOLD (a) Install the VSV for the EVAP to the upper intake manifold. (b) Connect the EVAP hose. (c) Connect the VSV connector for the EVAP. 5. INSTALL THROTTLE BODY COVER BRACKET Install the throttle body cover bracket with the bolt. 6. INSTALL FUEL PRESSURE PULSATION DAMPER (See page SF1 ) 7. INSTALL INTAKE AIR CONNECTOR 8. INSTALL THROTTLE BODY COVER 3617

60 SF24 SFI (2UZFE) INJECTOR INJECTOR ONVEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR SF0OR12 Ohmmeter B INSPECT INJECTOR RESISTANCE (a) Disconnect the 8 injector connectors. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 to 14.2 Ω at 20 C (68 F) If the resistance is not as specified, replace the injector. (c) Reconnect the 8 injector connectors. 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER 3609

61 SFI (2UZFE) INJECTOR REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page SF1 ) 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR SF27 SF REMOVE FUEL PRESSURE PULSATION DAMPER Remove the pulsation damper, upper gasket, fuel main hose and lower gasket. NOTICE: Put a shop rag under the delivery pipe. Slowly loosen the pulsation damper. 5. DISCONNECT PCV HOSE FROM PCV VALVE B07312 (c) (a) (b) 6. DISCONNECT VSV FOR EVAP (a) Disconnect the VSV connector for EVAP. (b) Disconnect the EVAP hose. (c) Remove the VSV for EVAP from the intake manifold. 7. REMOVE THROTTLE BODY COVER BRACKET Remove the bolt and throttle body cover bracket. Throttle Body Cover Bracket B16540 Clamp Clamp Clamp B DISCONNECT ENGINE WIRES (a) Disconnect the engine wire clamps from the No.1 engine hanger and engine wire bracket. (b) Disconnect the 2 wire clamps on the engine wire from the brackets on the RH delivery pipe. 9. REMOVE DELIVERY PIPES AND INJECTORS NOTICE: Be careful not to drop the injectors when removing the delivery pipes. Do not apply any load to the injector in horizontal direction. 3612

62 SF28 SFI (2UZFE) INJECTOR Fuel Return Pipe B17461 (a) (b) (c) (d) (e) (f) Remove the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Remove the bolt, 2 union bolts, 4 gaskets and front fuel pipe. Disconnect the 8 injector connectors. Remove the 4 nuts holding the delivery pipes to the lower intake manifold. Remove the 2 delivery pipes, 8 injectors, and 8 insulators. Remove the Oring and grommet from each injector. 3613

63 SF68 SFI (2UZFE) KNOCK SENSOR KNOCK SENSOR COMPONENTS SF0PR16 Suction Hose MAF Meter Wire Throttle Body Cover PS Air Hose Vacuum Hose PCV Hose Intake Air Connector B

64 SFI (2UZFE) KNOCK SENSOR SF69 Engine Wire Clamp 18 (185, 13) 18 (185, 13) Intake Manifold Assembly Injector Connector Fuel Return Hose Gasket VSV Connector for EVAP Fuel Inlet Hose Engine Wire 16 (163, 12) 16 (163, 12) Air Pump Assembly 20 (204, 15) Knock Sensor 1 20 (204, 15) Knock Sensor 2 N m (kgf cm, ft lbf) : Specified torque Nonreusable part B

65 SF70 SFI (2UZFE) KNOCK SENSOR INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. REMOVE INTAKE MANIFOLDS ASSEMBLY (See page EM36 ) SF1XU02 4. INSPECT KNOCK SENSORS 1 AND 2 (a) Disconnect the knock sensor connectors. (b) Using an ohmmeter, measure the resistance between terminals. Resistance: 120 to 280 kω at 20 C (68 F) HINT: If the resistance is not as specified, replace the sensor. B REMOVE KNOCK SENSOR (a) Disconnect the 2 knock sensor connectors. (b) Remove the 2 nuts and 2 knock sensors. B17475 Engine Rear Upper INSTALL KNOCK SENSOR (a) Install the 2 knock sensors with the 2 nuts as shown in the illustration. Torque: 20 N m (204 kgf cm, 15 ft lbf) (b) Connect the 2 knock sensor connectors. 7. INSTALL INTAKE MANIFOLD ASSEMBLY (See page EM60 ) 8. INSTALL INTAKE AIR CONNECTOR 9. INSTALL THROTTLE BODY COVER Upper Engine Rear 0 10 B

66 SFI (2UZFE) MASS AIR FLOW (MAF) METER COMPONENTS MASS AIR FLOW (MAF) METER SF39 SF0P112 MAF Meter MAF Meter Connector B

67 SF40 SFI (2UZFE) MASS AIR FLOW (MAF) METER RESISTANCE kω Air B E2G VG THA E2 SF0P210 INSPECTION 1. INSPECT OUTPUT VOLTAGE (a) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (b) Connect the positive (+) tester probe to terminal 3 (VG), and the negative () tester probe to terminal 2 (E2G). (c) Blow air into the MAF meter, and check if the voltage fluctuates. 2. INSPECT RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 (THA) and 5 (E2). Resistance: 12.5 to 16.9 kω at 20 C (4 F) 2.19 to 2.67 kω at 20 C (68 F) 0.50 to 0.68 kω at 60 C (140 F) Acceptable (212) (4) (32) (68) (104)(140)(176) TEMPERATURE C( F) B17464 VG E2G Air ECM B INSPECT MASS AIR FLOW METER (a) If using a handheld tester: (1) Connect the handheld tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Blow air into the MAF meter, and check that the air flow value of the CURRENT DATA changes. If operation is not as specified, check the MAF meter (see page DI531 and DI534 ) as well as the wiring and the ECM. (b) If not using a handheld tester: (1) Turn the ignition switch to the ON position. (2) Connect the positive tester probe of the voltmeter to terminal VG of the ECM and the negative tester probe of the voltmeter to terminal E2G of the ECM. (3) Blow air into the air flow meter, and check if the voltage fluctuates. If operation is not as specified, check the MAF meter (see page DI531 and DI534 ), the wiring and the ECM. Voltmeter B

68 SFI (2UZFE) SFI SYSTEM SFI SYSTEM PRECAUTION HINT: SF1 SF1XD02 All DTCs retained in the ECM will be erased when the negative () terminal cable is removed from the battery. If necessary, read the DTC before removing the negative () terminal cable from the battery. 1. BEFORE WORKING ON FUEL SYSTEM, DISCON NECT CABLE FROM NEGATIVE () BATTERY TERMI NAL 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH ER PARTS 4. MAINTENANCE PRECAUTIONS (a) To prevent engine misfire, these precautions should be taken. (1) Check the battery terminals are proper connected. (2) After repair, check that the ignition coil terminals and all other ignition system lines are reconnected securely. (3) When cleaning the engine compartment, be especially careful to protect the electrical system from water. (b) Observe the following when handling the air fuel ratio sensors and oxygen sensor. (1) Do not drop the sensor or hit it against another object. (2) The sensor should be free from any contact with water. 5. IF VEHICLE IS EQUIPPED WITH MOBILE RA DIO 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) Removal of the engine oil dipstick, oil filler cap, PCV hose, may break the engine. (b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head may result in air suction and break the engine. 7. ELECTRONIC CONTROL SYSTEM (a) Before removing SFI wiring connectors, terminals, first disconnect the power by turning the ignition switch off or disconnecting the negative () terminal cable from the battery. HINT: Be sure to check DTCs before disconnecting the negative () terminal cable from the battery. 3586

69 SF2 SFI (2UZFE) SFI SYSTEM (b) (c) (d) (e) (f) (g) (h) When installing the battery, be especially careful to correctly connect the positive (+) and negative () cables. Do not give a severe impact to the SFI parts during removal or installation. Handle all SFI parts carefully, especially the ECM. Be careful during troubleshooting. Numerous transistor circuits are used and even slight terminal contact can cause further trouble. Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting into the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care should be taken when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors. (2) Fully insert the connector and check that it is locked. SST FI2553 (i) Use SST for inspection or test of the injector or its wiring connector. SST FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe the following procedures: (1) Disconnect the circuit opening relay. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch off. (3) Put a container under the connecting part of the pressure line. (4) Slowly loosen the connection. (5) Disconnect the high fuel pressure line. (6) Reconnect the fuel pump connector. (b) When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe the following procedures: (1) Always use 2 new gaskets. (2) Tighten the union bolt by hand. New Gasket B

70 SFI (2UZFE) SFI SYSTEM SF3 SST Fulcrum Length 30 cm B16499 (3) Using SST, tighten the union bolt to the specified torque. SST ( ) Torque: 33 N m (340 kgf cm, 24 ft lbf) for use with SST 39 N m (400 kgf cm, 29 ft lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). ORing CORRECT WRONG (c) Observe the following precautions when removing or installing the injectors. (1) Never reuse the Oring. (2) When placing a new Oring on the injector, take care not to damage it in any way. (3) Coat a new Oring with spindle oil or gasoline before installing. Never use engine, gear or brake oil. Delivery Pipe B02714 ORing Grommet Injector Delivery Pipe (d) Install the injector to the delivery pipe and intake manifold as shown in the illustration. Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe or the intake manifold touches the Oring of the injector. Insulator Intake Manifold B04939 Quick Type Disconnect (e) Observe the following when disconnecting the fuel tube connector (quick type): (1) Check if there is any dirt in the pipe and around the connector before disconnecting the fuel tube connector. If necessary, clean the dirt away. (2) Disconnect the fuel pipe clamp from the connector. B17532 Quick Type Push Pull B11684 (3) Be sure to disconnect them by hand. (4) When the connector and the pipe are stuck, push and pull the connector. Then disconnect and pull it out. Do not use any tools at this time. (5) Check if there is any dirt or other foreign matter on the seal surface of the disconnected pipe. If necessary, clean the dirt away. (6) Do not damage the disconnected pipe and connector and prevent intrusion of foreign objects by covering them with a plastic bag. 3588

71 SF4 SFI (2UZFE) SFI SYSTEM Quick Type Push B11683 (f) Observe the following when connecting the fuel tube connector (quick type): (1) Check if there is any damage or foreign objects in the connected part of the pipe. (2) Match the axis of the connector with the axis of the pipe, and push into the connector until a click sound is heard. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe. Quick Type (3) After finishing the connection, pull the pipe and the connector to ensure it is secure. (4) Check to make sure no fuel leak is present. If the result is not specified, repair or replace. Pull B12520 Quick Type Install (5) Install the fuel pipe clamp to the connector. (6) Check to make sure no fuel leak is present. If the result is not specified, repair or replace. B17533 Metallic Type ORing Retainer Pipe Nylon Tube Housing B06584 (g) Observe the following when disconnecting the fuel tube connector (metallic type): HINT: The structure of the metallic connector is shown on the left. (1) Check if there is any dirt in the pipe and around the connector before disconnecting the fuel tube connector. If necessary, clean the dirt away. Metallic Type (2) Assemble SST to the connecting part, as shown in the illustration. SST SST B

72 SFI (2UZFE) SFI SYSTEM SF5 Metallic Type SST (3) Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector. Retainer (at 4 places) Insert B10035 Connector Metallic Type (4) While holding the SST, pull the connector towards the SST to put the retainers on the SST chamfered parts. (5) Slide the SST and connector together towards the fuel tube assembly. Pull B10036 Metallic Type Push B10485 (h) Observe the following when connecting the fuel tube connector (metallic type): (1) Check if there is any damage or foreign objects in the connected part of the pipe. (2) Match the axis of the connector with the axis of the pipe, and push into the connector until a click sound is heard. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe. Metallic Type (3) After finishing the connection, pull the pipe and the connector to ensure it is secure. (4) Check to make sure no fuel leak is present. If the result is not specified, repair or replace. Pull B10485 (i) Observer the following when handling the nylon tube: (1) Pay attention not to turn the connected part of the nylon tube and the quick connector with tube when connecting them. (2) Pay attention not to kink the nylon tube. (3) Do not remove the nylon tube. (4) Do not close the piping with the nylon tube by bending it. 3590

73 SF6 SFI (2UZFE) SFI SYSTEM DLC3 CAN VIM HandHeld Tester D13872 (j) Check that there is any fuel leak after maintenance anywhere on the fuel system. (1) Connect a handheld tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (2) Turn the ignition switch ON and push the handheld tester main switch ON. NOTICE: Do not start the engine. (3) Enter the following menus: DIAGNOSIS / EN HANCED OBDII / ACTIVE TEST / FUEL PUMP / SPD. (4) Please refer to the handheld tester operator s manual for further details. Fuel Return Hose Pinch B16500 (5) Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kpa (4 kgf/cm 2, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack. (6) Turn the ignition switch OFF. (7) Disconnect the handheld tester and CAN VIM from the DLC

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