Fuel TOYOTA LAND CRUISER 1996 J80 Owners Manual

SF0Y1−06
SF−22
−
SFI FUEL PRESSURE REGULATOR
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR
(a) Fully loosen the lock nut on the pressure regulator.
(b) Apply a light coat of gasoline to a new O −ring, and install
it to the pressure regulator.
(c) Insert the pressure regulator into the delivery pipe by hand completely.
(d) Turn the pressure regulator counterclockwise until the fuel outlet port faces in the direction indicated in the il-
lustration.
(e) Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
2. CONNECT FUEL RETURN HOSE TO FUEL PRES-
SURE REGULATOR
3. CONNECT V ACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR
4. START ENGINE AND CHECK FOR FUEL LEAKAGE
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−
SFI INJECTOR
SF−27
1996 LAND CRUISER (RM451U)
18. DISCONNECT PS RESERVOIR TANK
Remove the 3 bolts and disconnect the reservoir tank.
19. REMOVE ENGINE OIL DIPSTICK
20. DISCONNECT GROUND STRAP
21. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
22. DISCONNECT VACUUM HOSES FROM TVV
23. DISCONNECT NO.1 WATER BYPASS HOSE FROM
CYLINDER HEAD
24. REMOVE AIR INTAKE CHAMBER
Remove the 6 bolts, 2 nuts, air intake chamber and 2 gaskets.
25. REMOVE FUEL RETURN PIPE
(a) Disconnect the fuel hose from the fuel pressure regulator.
(b) Remove the 2 bolts and fuel return pipe.
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SF−28
−
SFI INJECTOR
1996 LAND CRUISER (RM451U)
26. REMOVE FUEL INLET PIPE
Remove the 2 union bolts, bolt, 4 gaskets and fuel pipe.
27. REMOVE DELIVERY PIPE AND INJECTORS
(a) Disconnect the 6 injector connectors.
(b) Remove the 3 bolts and delivery pipe together with the 6
injectors.
NOTICE:
Be careful not to drop the injectors when removing the de-
livery pipe.
(c) Remove the 6 insulators and 3 spacers from the intake manifold.
(d) Pull out the 6 injectors from the delivery pipe.
(e) Remove the O−ring and grommet from each injector.
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SF1EO−03
−
SFI INJECTOR
SF−29
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION:
Keep injector clean of sparks during the test.
(a) Connect SST (union and hose) to the fuel filter outlet with
the 2 gaskets and union bolt.
SST 09268−41046 (90405 −09015)
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Remove the fuel pressure regulator (See page SF−21).
(c) Install the O−ring to the fuel inlet of pressure regulator.
(d) Connect SST (hose) to the fuel inlet of the pressure regu-
lator with SST (union).
SST 09268−41046 (09268 −41091)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(e) Connect the fuel return hose to the fuel outlet of the pres-
sure regulator.
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FI4848
FI4849
SF−30
−
SFI INJECTOR
1996 LAND CRUISER (RM451U)
(f) Install the grommet and O−ring to the injector.
(g) Connect SST (union and hose) to the injector, and hold
the injector and union with SST (clamp).
SST 09268−41046
(h) Put the injector into the graduated cylinder.
HINT:
Install a suitable vinyl hose onto the injector to prevent gasoline
from splashing out.
(i) Remove the fuse cover on the instrument panel.
(j) Connect the TOYOTA hand−held tester to the DLC3.
(k) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(l) Select the active test mode on the TOYOTA hand −held
tester.
(m) Please refer to the TOYOTA hand −held tester operator’s
manual for further details.
(n) If you have no TOYOTA hand−held tester, connect the positive (+) and negative (−) leads from the battery to the
fuel pump connector (See page SF−14)
(o) Connect SST (wire) to the injector and battery for 15 se- conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
69 − 88 cm
3 (4.2 − 5.4 cu in.) per 15 seconds
Difference between each injector:
5 cm
3 (0.3 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop: One drop or less per minute
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative ( −) terminal cable from the bat-
tery.
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−
SFI INJECTOR
SF−31
1996 LAND CRUISER (RM451U)
(d) Remove SST.
SST 09268−41045
(e) Reinstall the fuel pressure regulator to the delivery pipe
(See page SF−22 ).
(f) Disconnect the TOYOTA hand− held tester from the
DLC3.
(g) Reinstall the fuse cover on the instrument panel.
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−
SFI INJECTOR
SF−33
1996 LAND CRUISER (RM451U)
(k) Connect the 6 injector connectors as shown.
2. INSTALL FUEL INLET PIPE
Install the fuel inlet pipe with 4 new gaskets, the 2 union bolts
and bolt.
Torque:
Union bolt: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt: 20 N·m (200 kgf·cm, 14 ft·lbf)
3. INSTALL FUEL RETURN PIPE
(a) Install the fuel return pipe with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the fuel hose to the fuel pressure regulator.
4. INSTALL AIR INTAKE CHAMBER
Install 2 new gaskets and the air intake chamber with the 6 bolts
and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
5. CONNECT NO.1 WATER BYPASS HOSE TO CYL- INDER HEAD
6. CONNECT VACUUM HOSES TO TVV
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SF0OZ−12
SF−36
−
SFI FUEL TANK AND LINE
664
Author: Date:
1996 LAND CRUISER (RM451U)
FUEL TANK AND LINE
COMPONENTS
CAUTION:
Always use new gaskets when replacing the fuel tank or component parts.
Apply the proper torque to all parts tightened.
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BO0919
Z00085
FU0041
SF0P0−06
−
SFI FUEL TANK AND LINE
SF−37
1996 LAND CRUISER (RM451U)
INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines for cracks or leakage, and all connec-
tions for deformation.
(b) Check the fuel tank vapor vent system hoses and connec-
tions 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 tube connections are as shown in the illustra- tion.
If a problem is found, repair or replace the part as necessary.
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SF1F7−01
P09134
OhmmeterContinuity
Ohmmeter Ohmmeter
Continuity
No Continuity FP
PR
FPR
+B1
+B2
P09135
Ohmmeter
No
Continuity
Battery
Ohmmeter
Continuity +B1
+B2 FP
PR
FPR
−
SFI FUEL PUMP RELAY
SF−57
685
Author: Date:
1996 LAND CRUISER (RM451U)
FUEL PUMP RELAY
INSPECTION
1. REMOVE FUEL PUMP RELAY
(a) Disconnect the fuel pump relay connector.
(b) Remove the bolt and fuel pump relay.
2. INSPECT FUEL PUMP RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals +B1 and FPR.
(b) Check that there is continuity between terminals +B2 and
FP.
(c) Check that there is no continuity between terminals +B2
and PR.
If continuity is not as specified, replace the relay.
3. INSPECT FUEL PUMP RELAY OPERATION
(a) Apply battery voltage across terminals +B1 and FPR.
(b) Using an ohmmeter, check that there is no continuity be- tween the +B2 and FP.
(c) Check that there is continuity between terminals +B2 and
PR.
If operation is not as specified, replace the relay.
4. REINSTALL FUEL PUMP RELAY
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