1996 TOYOTA T100 fuel pump

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− MFI (3RZ−FE)FUEL PUMP
MF−11
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MF−10).

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MF−12
− MFI (3RZ−FE)FUEL PUMP
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page MF−9).

Downloaded from www.Manualslib.com manuals search engine SF – SFI SYSTEM (5VZ-FE)

SFI SYSTEM SF-1
FUEL PUMP SF-5
FUEL PRESSURE REGULATOR SF-14
INJECTOR SF-18
FUEL TANK AND LINE SF-25
MASS AIR FLOW (MAF) METER SF-28
THROTTLE BODY SF-31
IDLE AIR CONTROL (IAC) VALVE SF-39
EFI MAIN RELAY SF-45
CIRCUIT OPENING RELAY SF-46
VSV FOR FUEL PRESSURE CONTROL SF-47
VSV FOR EXHAUST GAS CONTROL
VALVE SF-49
VSV FOR EVAPORATIVE EMISSION
(EVAP) SF-50
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR SF-51
KNOCK SENSOR SF-54
EXHAUST GAS RECIRCULATION
(EGR) GAS TEMPERATURE SENSOR SF-59
HEATED OXYGEN SENSOR SF-60
ENGINE CONTROL MODULE (ECM) SF-61
FUEL CUT RPM SF-63

Downloaded from www.Manualslib.com manuals search engine P21154
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.

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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.