TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P03244Press Down Lock
P03245LockInsert
FI2553
SF−2
− SFI (5VZ−FE)SFI SYSTEM
1008 Author: Date:
1996 TOYOTA T100 (RM449U)
6. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, 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.
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (−) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(1) Release the lock and pull out the connector, pulling
on the connectors.
(2) Fully insert the connector and check that it is locked.
(i) When inspecting a connector with a volt/ohmmeter
(1) Carefully take out the water−proofing rubber if it is
a water−proof type connector.
(2) Insert the test probe into the connector from the wir-
ing side when checking the continuity, amperage or
voltage.
(3) Do not apply unnecessary force to the terminal.
(4) After checking, install the water−proofing rubber on
the connector securely.
(5) Use SST for inspection or test of the injector or its
wiring connector.
SST 09842−30070

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P19985
FI1654
30 cm
SST
Fulcrum Length
− SFI (5VZ−FE)SFI SYSTEM
SF−3
1009 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque:
34.3 N·m (350 kgf·cm, 25 ft·lbf)
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.).

Downloaded from www.Manualslib.com manuals search engine B00566
GrommetDelivery PipeCORRECT
WRONG
New O−Ring
Injector
B00567
Delivery Pipe
O−Ring
Grommet
O−Ring Grommet
Spacer
FI7231
TOYOTA Hand−Held Tester
DLC3
P21058
SF−4
− SFI (5VZ−FE)SFI SYSTEM
1010 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(d) Install the injector to the delivery pipe and intake manifold
as shown in the illustration.
(e) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
(1) Connect the TOYOTA hand−held tester to the
DLC3.
(2) Turn the ignition switch ON and push the TOYOTA
hand−held tester main switch ON.
NOTICE:
Do not start the engine.
(3) Select the active test mode on the TOYOTA hand−
held tester.
(4) Please refer to the TOYOTA hand−held tester oper-
ator ’s manual for further details.
(5) If you have no TOYOTA hand−held tester, connect
the positive (+) and negative (−) leads from the bat-
tery to the fuel pump connector.
(See page SF−10)
(6) Pinch the fuel return hose.
The pressure in the high pressure line will rise to
approx. 400 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.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand−held tester from the
DLC3.

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TOYOTA Hand−Held Tester
DLC3
P21057
SF0BT−02
P21210
− SFI (5VZ−FE)FUEL PUMP
SF−5
1011 Author: Date:
1996 TOYOTA T100 (RM449U)
FUEL PUMP
ON−VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and push the TOYOTA hand−
held tester main switch ON.
NOTICE:
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand−held
tester.
(d) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(e) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector.
(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check these parts:
H−fuse (ALT 80A)
M−fuses (AM1 40A, AM2 30A)
Fuses (EFI 15A, IGN 7.5A)
EFI main relay
Circuit opening relay
Fuel pump
ECM
Wiring connections
(g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand−held tester 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 bat-
tery.
(c) Remove the 6 bolts, and disconnect the No.2 timing belt
cover.
(d) Remove the union bolt holding the fuel pipe to the delivery
pipe and gasket.
CAUTION:
Put a shop towel under the delivery pipe. Slowly loosen the
union bolt.

Downloaded from www.Manualslib.com manuals search engine P21220
SST (Union)
SST
(Union Bolt) Gasket
P21224
SF−6
− SFI (5VZ−FE)FUEL PUMP
1012 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Install SST (pressure gauge) to the delivery pipe with the
2 gaskets and SST (union and union bolt).
SST 09268−45012
Torque:34.3 N·m (350 kgf·cm, 25 ft·lbf)
(f) Wipe off any splattered gasoline.
(g) Connect the TOYOTA hand−held tester to the DLC3.
(See on−vehicle inspection in fuel pump)
(h) Reconnect the negative (−) terminal cable to the battery.
(i) Turn the ignition switch ON.
(j) Measure the fuel pressure.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 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
VSV for fuel pressure control
(k) Disconnect the TOYOTA hand−held tester from the
DLC3.
(l) Reinstall the No.2 timing belt cover with the 6 bolts.
(m) Start the engine.
(n) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator, and plug the hose end.
(o) Measure the fuel pressure at idle.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
(p) Reconnect the vacuum sensing hose to the fuel
pressure regulator.
(q) Measure the fuel pressure at idle.
Fuel pressure:
226 − 265 kPa (2.3 − 2.7 kgf/cm
2, 33 − 38 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(r) Stop the engine.
(s) 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.
(t) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268−45012
(u) Remove the other union bolt, 3 gaskets and fuel pipe
from the delivery pipes.

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SF−7
1013 Author: Date:
1996 TOYOTA T100 (RM449U)
(v) Reinstall the fuel pipe with 4 new gaskets and the 2 union
bolts.
Torque:34.3 N·m (350 kgf·cm, 25 ft·lbf)
(w) Reconnect the negative (−) terminal cable to the battery.
(x) Check for fuel leakage.

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SF−8
− SFI (5VZ−FE)FUEL PUMP
1996 TOYOTA T100 (RM449U)
FUEL PUMP
COMPONENTS

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P22396
− SFI (5VZ−FE)FUEL PUMP
SF−9
1996 TOYOTA T100 (RM449U)
REMOVAL
CAUTION:
Do not smoke or work near an open flame when working on
the fuel pump.
1. REMOVE FUEL TANK
HINT:
Check for fuel leakage.
2. REMOVE FUEL PUMP BRACKET ASSEMBLY FROM
FUEL TANK
(a) Disconnect the fuel pump connector from the clamp.
(b) Remove the 7 bolts.
Torque: 3.9 N·m (40 kgf·cm, 35 in.·lbf)
(c) Pull out the pump bracket assembly.
(d) Remove the gasket from the pump bracket.
HINT:
Install a new gasket to the pump bracket.

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SF0BW−01
P15059
SF−10
− SFI (5VZ−FE)FUEL PUMP
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Disconnect the fuel pump connector.
(b) Pull off the lower side of the fuel pump from the pump
bracket.
(c) Disconnect the fuel hose from the fuel pump, and remove
the fuel pump.
(d) Remove the rubber cushion from the fuel pump.
2. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Using a small screwdriver, remove the clip.
HINT:
Install the pump filter with a new clip.
(b) Pull out the pump filter.

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− SFI (5VZ−FE)FUEL PUMP
SF−11
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT FUEL PUMP RESISTANCE
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: 0.2 − 3.0 Ω at 20°C (68°F)
If the resistance is not as specified, replace the fuel pump and/
or set plate.
2. INSPECT FUEL PUMP OPERATION
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
plate.