fuel pump TOYOTA SUPRA 1995 Service Repair Manual

CAUTION:
wBe sure to connect both the high and low pressure
quick±connectors onto the A/C system when evacuating.
If only one side is connected, the system would be open
to atmosphere through the other connector, making it
impossible to maintain vacuum.
wBe sure to turn off the manifold gauge valve immediately
after evacuating the system. Then you may switch off the
vacuum pump.
PRECAUTIONS WHEN CHARGING
REFRIGERANT
1. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH
REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system, oil
lubrication will be insufficient and compressor burnout may
occur, so take care to avoid this.
2. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILST COMPRESSOR IS OPERATING
If the high pressure valve is opened, refrigerant flows in the
reverse direction and could cause the charging cylinder to
rupture, so open and close the low pressure valve only.
3. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as in-
sufficient cooling, poor fuel economy, engine overheating
etc.
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
deploy, possibly leading to a serious accident.
During removal or installation of the parts and the yellow wire
harness and connector for the airbag is necessary, refer to
the precautionary notices in the RS section before carrying
out operation. AC±6
± AIR CONDITIONING SYSTEMGENERAL DESCRIPTION

INTRODUCTIONGLOSSARY OF SAE AND TOYOTA TERMS -
IN-7
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE
recommendations, as well as their Toyota equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )--ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal-
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric Pressure-
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection-
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position-
CTOXContinuous Trap Oxidizer-
CTPClosed Throttle Position-
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition-
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Toyota Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode-
ECLEngine Control Level-
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only
MemoryElectrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory(EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionToyota Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control-
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory-
FEPROMFlash Erasable Programmable Read Only Memory-
FFFlexible Fuel-
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
HO2SHeated Oxygen SensorHeated Oxygen Sensor (HO2S)
IN016-02

GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE
recommendations, as well as their Toyota equivalents.
 
 
SAE ABBREVI±
ATIONS 
 SAE TERMS
 
 
TOYOTA TERMS
( ) ±± ABBREVIATIONS
 A/C Air Conditioning Air Conditioner
 ACL Air Cleaner Air Cleaner
AIRSecondary Air InjectionAir Injection (AI) AP Accelerator Pedal ± B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure ±
 CAC Charge Air Cooler Intercooler
 CARB Carburetor Carburetor
 CFI Continuous Fuel Injection ±
 CKP Crankshaft Position Crank Angle
CLClosed LoopClosed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position ±
 CTOX Continuous Trap Oxidizer ±
 CTP Closed Throttle Position Idle ON (IDL ON)
 DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
 DI Distributor Ignition ±
 
 
DLC1
DLC2
DLC3 
 
Data Link Connector 1
Data Link Connector 2
Data Link Connector 3 
 
1: Check Connector
2: Toyota Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
 DTC Diagnostic Trouble Code Diagnostic Code
 DTM Diagnostic Test Mode ±
 ECL Engine Control Level ±
 ECM Engine Control Module Engine ECU (Electronic Control Unit)
 ECT Engine Coolant Temperature Coolant Temperature, Water Temperature
(THW)
 
 
 
 
EEPROM
 
 
 
 
Electrically Erasable Programmable Read Only
Memory
 
 
 
 
Electrically Erasable Programmable Read Only
Memory (EEPROM),
Erasable Programmable Read Only Memory
(EPROM)
 
 
EFE 
 
Early Fuel Evaporation 
 
Cold Mixture Heater (CMH), Heat Control Valve
(HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR) EI Electronic Ignition Toyota Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
 EVAP Evaporative Emission Evaporative Emission Control (EVAP)
 FC Fan Control ±
 FEEPROM Flash Electrically Erasable Programmable
Read Only Memory ±
 
 FEPROM
 
 Flash Erasable Programmable Read Only
Memory 
 ±
 FF Flexible Fuel ±
 FP Fuel Pump Fuel Pump
 GEN Generator Alternator
 GND Ground Ground (GND)
HO2SHeated Oxygen SensorHeated Oxygen Sensor (HO2S)
± INTRODUCTIONGLOSSARY OF SAE AND TOYOTA TERMSIN±39

12. REMOVE AIR INTAKE CHAMBER STAYS
(a) Remove the bolt, nut and No.1 stay.
(b) Remove the bolt, nut and No.2 stay.
13. REMOVE NO.2 VACUUM PIPE AND VSV ASSEMBLY
14. REMOVE NO.3 TIMING BELT COVER
(a) Remove the oil filler cap.
(b) Using a 5 mm hexagon wrench, remove the 6 bolts and timing
belt cover.
15. REMOVE CYLINDER HEAD REAR COVER
Using a 5 mm hexagon wrench, remove the 4 bolts and cylin-
der head rear cover.
16. D I S C O N N E C T H I G H ± T E N S I O N C O R D S F R O M
CYLINDER HEAD COVERS
(See step 4 in high±tension cords and cord clamps re-
moval in Ignition System)
17. REMOVE DISTRIBUTOR AND CORDS ASSEMBLY
(See steps 1 to 3 in distributor removal in Ignition Sys-
tem)
18. REMOVE SPARK PLUGS
19. RE MO V E TIMING BE LT FRO M CAMS HAFT TIMING
PULLEYS
(See steps 5 to 8 in timing belt removal)
NOTICE:
wSupport the timing belt, so that the meshing of the crank-
shaft timing pulley and timing belt does not shift.
wBe careful not to drop anything inside the timing belt cov-
er.
wDo not allow the timing belt to come into contact with oil,
water or dust.
20. REMOVE WATER BYPASS OUTLET AND NO.1 WATER
BYPASS PIPE
(See step 13 in water pump removal in Cooling System)
21. DISCONNECT FUEL RETURN HOSE
(a) Disconnect the fuel return hose from the fuel return pipe. Plug
the hose end.
(b) Disconnect the fuel return hose from the oil dipstick guide.
22. REMOVE ENGINE WIRE BRACET
Remove the bolt and bracket, disconnect the engine wire the
intake manifold stay. EG±42
± ENGINEENGINE MECHANICAL

23. REMOVE OIL DIPSTICK GUIDES FOR ENGINE AND
TRANSMISSION
(a) Remove the 2 bolts.
(b) Pull out the dipstick guide together with the dipstick.
(c) Remove the O±ring from the dipstick guide.
24. REMOVE STARTER
(See starter removal in Starting System)
25. REMOVE AIR INTAKE CHAMBER
(a) Except California:
Disconnect the vacuum sensing hose from the fuel pressure
regulator.
(b) Remove the bolt holding the engine wire protector to the the
air intake chamber.
(c) Remove the 5 bolts, nut, air intake chamber and gasket.
26. REMOVE VACUUM CONTROL VALVE SET
(a) Disconnect the VSV connector.
(b) Remove the 2 nuts and vacuum control valve set.
27. DISCONNECT ENGINE WIRE
(a) Remove the bolt, and disconnect the engine wire bracket
from the water pump.
(b) Remove the 2 bolts, and disconnect the 2 ground straps from
the intake manifold.
(c) Remove the 2 bolts, and disconnect the 2 wire clamps from
the intake manifold.
(d) Disconnect these connectors:
w6 injector connectors
wECT sensor connector
wECT sender gauge connector
± ENGINEENGINE MECHANICALEG±43

4. REMOVE DRIVE BELT
Loosen the drive belt tension by turning the drive belt tension-
er clockwise, and remove the drive belt.
5. REMOVE WATER OUTLET AND NO.1 WATER BYPASS
PIPE
(a) Disconnect the upper radiator hose from the water outlet.
(b) Disconnect the ECT sensor and sender gauge connectors.
(c) Remove the 2 bolts, water outlet and gasket.
(d) Remove the No.1 water bypass pipe and 2 O±rings.
6. DISCONNECT PS PUMP WITHOUT DISCONNECTING
HOSES
(a) Disconnect these hoses:
(1) Air hose from throttle body
(2) Air hose from air intake chamber
(b) Remove the 2 bolts, and disconnect the pump housing from
the pump bracket.
HINT: Put aside the pump housing, and suspend it securely.
7. DISCONNECT FUEL RETURN HOSE
Disconnect the fuel return hose from the fuel return pipe. Plug
the hose end.
8. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(See injector removal in SFI System)
± ENGINEENGINE MECHANICALEG±47

8. INSTALL FUEL INLET PIPE
(a) Connect the fuel inlet pipe with 2 new gaskets and the union
bolt.
Torque: 42 NVm (420 kgfVcm, 30 ftVlbf)
(b) Install the clamp bolt to the intake manifold.
9. INSTALL FUEL PRESSURE PULSATION DAMPER
(See fuel pressure pulsation damper installation in SFI
System)
10. INSTALL INTAKE MANIFOLD STAY
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
11. INSTALL WATER OUTLET AND NO.1 BYPASS HOSE
ASSEMBLY
12. CONNECT ENGINE WIRE
(a) Install the engine wire protector to the intake manifold with
the 3 nuts.
(b) Connect these connectors:
w6 injector connectors
HINT: The No.1, No.3 and No.5 injector connectors are dark
gray, and the No.2, No.4 and No.6 injector connectors are
gray.
wECT sensor connector
wECT sender gauge connector
(c) Install the 2 wire clamps to the intake manifold with the bolts.
(d) Install the 2 ground straps to the intake manifold with the
bolts.
(e) Install the engine wire bracket to the water pump with the bolt.
13. INSTALL VACUUM CONTROL VALVE SET
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
14. INSTALL AIR INTAKE CHAMBER
(a) Install a new gasket and the intake chamber with the 5 bolts
and nut.
Torque: 27 NVm (280 kgfVcm, 20 ftVlbf)
(b) Install the bolt holding the engine wire protector to the air
intake chamber.
(c) Except California:
Connect the vacuum sensing hose to the fuel pressure regu-
lator.
15. INSTALL STARTER
(See starter removal in Starting System)
16. INS TALL OIL DIP S TICK GUIDE S FO R ENG INE AND
TRANSMISSION
(a) Install a new O±ring to the dipstick guide.
(b) Apply soapy water to the O±ring.
(c) Connect the dipstick guide end to the oil pan.
(d) Install the 2 dipstick guides with the 2 bolts.
17. INSTALL ENGINE WIRE BRACKET
18. CONNECT FUEL RETURN HOSE
± ENGINEENGINE MECHANICALEG±67

w6 injectors connectors
HINT: The No.1, No.3 and No.5 injector connectors are dark
gray, and the No.2, No.4 and No.6 injector connectors are
gray.
w2 camshaft position sensor connectors
w3 engine wire clamps to injector holders
16. INSTALL AIR INTAKE CHAMBER ASSEMBLY
(See injector installation in SFI System)
17. CONNECT FUEL RETURN HOSE
18. INSTALL PS PUMP
Torque: 58 NVm (590 kgfVcm, 43 ftVlbf)
19. INSTALL WATER OUTLET AND NO.1 WATER BYPASS
PIPE
(a) Install 2 new O±rings to the No.1 water bypass pipe.
(b) Apply soapy water to the O±rings.
(c) Install the No.1 water bypass pipe to the water pump.
(d) Install a new gasket and the water outlet with the 2 bolts.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
(e) Connect the ECT sensor and sender gauge connectors.
(f) Connect the upper radiator hose to the water outlet.
20. INSTALL DRIVE BELT
Install the drive belt by turning the drive belt tensioner clock-
wise.
21. M/T:
INSTALL DRIVE BELT TENSIONER DAMPER
(See step 19 in timing belt installation)
22. INSTALL EXHAUST MANIFOLD
(a) P la ce 2 ne w ga ske ts to th e cylinder head facing the
protrusion as shown.
(b) Install the exhaust manifold with 12 new nuts, in several
passes, in the sequence shown.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
23. INSTALL TURBOCHARGER
(See turbocharger installation in Turbocharger System)
± ENGINEENGINE MECHANICALEG±71

ENGINE REMOVAL (2JZ±GE)
1. REMOVE HOOD
2. REMOVE RADIATOR ASSEMBLY
(See radiator removal in Cooling System)
3. DRAIN ENGINE OIL
4. DRAIN FUEL FROM FUEL TANK
5. DISCONNECT CONTROL CABLES FROM THROTTLE
BODY
Disconnect these cables:
wAccelerator cable
wCruise control actuator cable
6. REMOVE AIR CLEANER, VAF METER AND INTAKE AIR
CONNECTOR PIPE ASSEMBLY
(a) Disconnect the high±tension cord from the ignition coil.
(b) Disconnect the high±tension cord from the clamp on the air
cleaner.
(c) Disconnect the VAF meter connector.
(d) Disconnect the engine wire from the VAF meter.
(e) Disconnect these hoses:
(1) PS air hose from No.4 timing belt cover
(2) PCV hose from No.2 cylinder head cover
(f) Loosen the hose clamp bolt holding the intake air connector
pipe to the throttle body.
(g) Remove the 3 bolts, air cleaner, VAF meter and intake air
connector pipe assembly.
7. REMOVE DRIVE BELT, FAN, FLUID COUPLING
ASSEMBLY AND WATER PUMP PULLEY
(See step 6 in water pump removal in Cooling System)
8. REMOVE CHARCOAL CANISTER
9. DISCONNECT HEATER WATER HOSES
10. DISCONNECT BRAKE BOOSTER VACUUM HOSE
11. DISCONNECT EVAP HOSE
12. DISCONNECT WIRES AND CONNECTORS
(a) Disconnect the noise filter connector.
(b) Disconnect the ignition coil connector.
(c) Disconnect the engine wire from the wire clamp. EG±78
± ENGINEENGINE MECHANICAL

13. DISCONNECT FUEL HOSES
(a) Remove the union bolt and 2 gaskets, disconnect the fuel
inlet hose.
HINT:
wPut a suitable container or shop rag under the fuel pipe
support.
wSlowly loosen the union bolt.
(b) Suspend the hose union end upward.
(c) Disconnect the fuel return hose from the oil dipstick guide.
(d) Disconnect the fuel return hose from the fuel return hose.
Plug the hose end.
14. REMOVE ENGINE WIRE BRACKET
Remove the bolt and bracket, and disconnect the engine wire
from the intake manifold stay.
15. DISCONNECT PS PUMP WITHOUT DISCONNECTING
HOSES
(a) Remove the 3 bolts, plate washer and pump front bracket.
(b) Disconnect these hoses:
(1) Air hose from No.4 timing belt cover
(2) Air hose from air intake chamber
(c) Disconnect the pump housing from the pump bracket.
HINT: Put aside the pump housing, and suspend it.
(d) Remove the 2 bolts and pump rear stay.
(e) Remove the 2 bolts and pump bracket. EG±80
± ENGINEENGINE MECHANICAL