1996 TOYOTA T100 fuel pump

Downloaded from www.Manualslib.com manuals search engine MF – MFI SYSTEM (3RZ-FE)

MFI SYSTEM MF-1
FUEL PUMP MF-5
FUEL PRESSURE REGULATOR MF-13
INJECTOR MF-16
FUEL TANK AND LINE MF-23
THROTTLE BODY MF-25
IDLE AIR CONTROL (IAC) VALVE MF-31
MASS AIR FLOW (MAF) METER MF-36
EFI MAIN RELAY MF-40
CIRCUIT OPENING RELAY MF-41
VSV FOR EVAPORATIVE EMISSION
(EVAP) MF-43
VSV FOR EXHAUST GAS
RECIRCULATION (EGR) MF-44
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR MF-45
INTAKE AIR TEMPERATURE (IAT)
SENSOR MF-46
KNOCK SENSOR MF-47
EXHAUST GAS RECIRCULATION
(EGR) GAS TEMPERATURE SENSOR MF-48
HEATED OXYGEN SENSOR MF-49
ENGINE CONTROL MODULE (ECM) MF-50
FUEL CUT RPM MF-54

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3
MF−4
− MFI (3RZ−FE)MFI SYSTEM
956 Author: Date:
1996 TOYOTA T100 (RM449U)
(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 ignition switch ON and 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 MF−10)
(6) Pinch the fuel return hose. The pressure in 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 to
hose to crack.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand−held tester from the
DLC3.

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3SF0AG−03
P24761
− MFI (3RZ−FE)FUEL PUMP
MF−5
957 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 TOYOTA hand−held tes-
ter 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.
(See page MF−10)
(f) Check that there is pressure in the hose from the fuel filter.
HINT:
At this time, you will hear fuel return noise.
If there is no pressure, check these parts:
Fusible links (AM1 40A, AM2 30A, ALT 80A)
Fuses (EFI 15A, IGN 7.5A)
EFI main relay
Fuel pump
ECM
Wiring connections
(g) Turn the ignition switch to LOCK.
(h) Remove the TOYOTA hand−held tester.
2. CHECK FUEL PRESSURE
(a) Check that the battery voltage is above 12 volts.
(b) Disconnect the negative (−) terminal cable from the bat-
tery.
(c) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet pipe from the delivery pipe.
HINT:
Put a suitable container or shop rag under the delivery
pipe.
Slowly loosen the union bolt.

Downloaded from www.Manualslib.com manuals search engine P24762
FI7231
TOYOTA Hand−Held Tester
DLC3
MF−6
− MFI (3RZ−FE)FUEL PUMP
958 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Install the fuel inlet pipe and SST (pressure gauge) to the
delivery pipe with 3 gaskets and SST (union bolt).
SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(e) Wipe off any splattered gasoline.
(f) Connect the TOYOTA hand−held tester to the DLC3.
(g) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(h) Select the active test mode on the TOYOTA hand−held
tester.
(i) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(j) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector.
(See page MF−10)
(k) Reconnect the negative (−) terminal cable to the battery.
(l) Turn the ignition switch ON.
(m) 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
Injectors
(n) Remove the TOYOTA hand−held tester.
(o) Start the engine.
(p) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator, and plug the hose end.
(q) Measure the fuel pressure at idle.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
(r) Reconnect the vacuum sensing hose to the fuel pressure
regulator.
(s) Measure the fuel pressure at idle.
Fuel pressure:
206 − 255 kPa (2.1 − 2.6 kgf/cm
2, 31 − 37 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(t) Stop the engine.

Downloaded from www.Manualslib.com manuals search engine P24763
− MFI (3RZ−FE)FUEL PUMP
MF−7
959 Author: Date:
1996 TOYOTA T100 (RM449U)
(u) 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 injector.
(v) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove SST
to prevent gasoline from splashing.
SST 09268−45012
(w) Reconnect the fuel inlet pipe to the delivery pipe with 2
new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(x) Reconnect the negative (−) terminal cable to the battery.
(y) Check for fuel leakage.

Downloaded from www.Manualslib.com manuals search engine SF0AH−03
MF−8
− MFI (3RZ−FE)FUEL PUMP
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine SF0AI−02
B02579
− MFI (3RZ−FE)FUEL PUMP
MF−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
(See page MF−23)
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:
At the time assembly please refer to the following items.
Install the fuel pump bracket with a new gasket.

Downloaded from www.Manualslib.com manuals search engine SF0AJ−03
P15055
P15059
MF−10
− MFI (3RZ−FE)FUEL PUMP
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
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 the switching
at the battery side.
If operation is not as specified, replace the fuel pump and/or
plate.
3. 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.
4. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Using a small screwdriver, remove the clip.
(b) Pull out the pump filter.