Toyota Tacoma 2002-06

Sequential Multi-Port Fuel Injection System (SFI)

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Fuel Pressure Regulator



Removal & Installation
1gr-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge fuel system pressure.
  4.  
  5. Disconnect cable from negative battery terminal.
  6.  
  7. Remove v-bank cover.
  8.  
  9. Remove air cleaner assembly.
  10.  
  11. Disconnect fuel pipe sub-assy no.2.
  12.  
  13. Remove the 2 bolts, then remove the fuel pressure regulator.
  14.  
  15. Remove the vacuum hose.
  16.  

To install:

  1. Install the vacuum hose.
  2.  
  3. Apply a light coat of spindle oil or gasoline to a new O-ring and install it onto the fuel pressure regulator.
  4.  
  5. Install the fuel pressure regulator with the 2 bolts and tighten to 9.0 Nm (80 in. lbs.).
  6.  
  7. Connect fuel pipe sub-assembly no.2.
  8.  
  9. Install air cleaner assembly.
  10.  
  11. Install v-bank cover.
  12.  
  13. Connect cable to negative battery terminal.
  14.  
  15. Check for fuel leakage.
  16.  

2RZ-FE & 3RZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain engine coolant.
  4.  
  5. Disconnect accelerator cable from throttle body.
  6.  
  7. Disconnect throttle cable from throttle body.
  8.  
  9. Disconnect the 2 wire clamps from the air cleaner hose.
  10.  
  11. Loosen the air cleaner hose clamps, remove the air cleaner together with the resonator.
  12.  
  13. Disconnect the PCV hose and EVAP hose.
  14.  
  15. Disconnect the air hose for PS idle-up.
  16.  
  17. Disconnect the throttle position sensor connector.
  18.  
  19. Disconnect the IAC valve connector.
  20.  
  21. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the air intake chamber.
  22.  
  23. Disconnect the water bypass hoses from the throttle body, and remove the throttle body.
  24.  
  25. Remove the throttle body gasket.
  26.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the throttle body fasteners to 20 Nm (14 ft. lbs.).
  2.  

2TR-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge fuel system pressure.
  4.  
  5. Disconnect cable from negative battery terminal
  6.  
  7. Remove intake air connector.
  8.  
  9. Disconnect fuel hose no.2.
  10.  
  11. Disconnect the throttle w/ motor body connectors.
  12.  
  13. Disconnect the VSV connector.
  14.  
  15. Disconnect the engine wire harness clamp.
  16.  
  17. Remove the bolt, then remove the harness clamp bracket.
  18.  
  19. Remove the 3 bolts, then remove the fuel pressure regulator.
  20.  

To install:

  1. Apply a light coat of gasoline or spindle oil to the O-ring.
  2.  
  3. Install the fuel pressure regulator with the 3 bolts and tighten to 8.5 Nm (75 in. lbs.).
  4.  
  5. Install the harness clamp bracket with the bolt and tighten to 8.2 Nm (73 in. lbs.).
  6.  
  7. Connect the engine wire harness clamp.
  8.  
  9. Connect the VSV connector.
  10.  
  11. Connect the throttle w/ motor body connectors.
  12.  
  13. Connect fuel hose no.2.
  14.  
  15. Install intake air connector.
  16.  
  17. Connect cable to negative battery terminal.
  18.  
  19. Check for fuel leakage.
  20.  

5vz-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain engine coolant.
  4.  
  5. Disconnect accelerator cable from throttle body.
  6.  
  7. Remove air cleaner hose.
  8.  
  9. Disconnect the throttle position sensor connector.
  10.  
  11. Disconnect the throttle control motor connector.
  12.  
  13. Disconnect the accelerator pedal position sensor connector.
  14.  
  15. Disconnect the air hose.
  16.  
  17. Disconnect the 2 water bypass hoses.
  18.  
  19. Remove the 2 bolts, 2 nuts, throttle body and gasket.
  20.  

To install:

  1. Place a new gasket on the air intake chamber facing the protrusion upward.
  2.  
  3. Install the throttle body with the 2 bolts and 2 nuts and tighten to 18 Nm (13 ft. lbs.).
  4.  
  5. Connect the throttle position sensor connector.
  6.  
  7. Connect the throttle control motor connector.
  8.  
  9. Connect the accelerator pedal position sensor connector.
  10.  
  11. Connect the air hose.
  12.  
  13. Connect the 2 water bypass hoses.
  14.  
  15. Connect accelerator cable to throttle body.
  16.  
  17. Install air cleaner hose.
  18.  
  19. Fill with engine coolant.
  20.  
  21. Start engine and check for coolant leaks.
  22.  

Fuel Pump



Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel from the fuel tank.
  8.  
  9. Remove or disconnect the following:

    Fuel tank
     
    Fuel pump connector from the clamp
     
    Access plate bolts, then pull out the fuel pump assembly from the fuel tank
     
    Gasket(s) from the pump bracket
     
    Fuel pump connector
     
    Bracket from the lower side of the fuel pump
     
    Fuel pump from the fuel hose
     
    Rubber cushion, the clip and the fuel filter at the bottom of the fuel pump
     

  10.  

To install:

Click image to see an enlarged view

Fig. Fuel pump and related components-2001-2004

  1. Install or connect the following:

    Fuel pump filter to the fuel pump with a new clip
     
    Fuel pump to the fuel pump bracket
     
    Fuel hose to the outlet port of the fuel pump
     
    Fuel pump connector
     
    Fuel pump assembly with a new gasket(s). Tighten the bolts to 31 inch lbs. (4 Nm).
     
    Fuel pump connector to the clamp
     
    Fuel tank
     
    All electrical and fuel connections
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel from the fuel tank.
  8.  
  9. On vehicles equipped with off road package and 4.0L engine, remove the number one fuel tank protector subassembly.
  10.  
  11. Remove the fuel tank.
  12.  
  13. Remove the fuel tank main hose and the return hose.
  14.  
  15. Remove the fuel pump and gauge assembly retainer from its mounting, using tool SST09808-14020 or equivalent.
  16.  
  17. Pull the fuel pump and gauge assembly out of the fuel tank. Be careful not to bend the arm of the sender. Remove and discard the gasket.
  18.  
  19. Disconnect the connector from the assembly.
  20.  
  21. Disengage the claw fitting and remove the sender gauge by sliding it forward.
  22.  
  23. Disengage the five claw fittings and remove the fuel pump tank. Separate the connector and disengage the clamp.
  24.  
  25. Disengage the clamp and then disconnect the connector.
  26.  
  27. Disengage the five claw fittings and separate the fuel pump from the fuel pump case. Disconnect the connector from the fuel pump.
  28.  
  29. Remove the fuel filter from the fuel pump.
  30.  

To install:

Click image to see an enlarged view

Fig. Fuel pump and related components-2005-2006

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Start the engine and check for leaks, correct as required.
  4.  

Fuel Rail & Injectors



Removal & Installation
1gr-FE Engine


Click image to see an enlarged view

Fig. Fuel injector and related components-4.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant. Remove the V bank cover.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Remove the intake manifold.
  12.  
  13. Disconnect and plug the fuel line hoses.
  14.  
  15. Disconnect the fuel injector connectors. Remove the six bolts and the fuel rail together with the injectors.
  16.  
  17. Pull the injectors out of the fuel rail.
  18.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new gaskets and O-rings, as required.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

2RZ-FE & 3RZ-FE Engines


Click image to see an enlarged view

Fig. Fuel injector and related components-2.4L and 2.7L (3RZ-FE/M) engines

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    WARNING
    The injectors are only retained by their O-rings and will tend to drop out of the fuel rail.



    Throttle body
     
    Fuel injector electrical connectors
     
    Crankshaft Position (CKP) sensor connector
     
    Knock Sensor (KS) connector
     
    Data Link Connector 1 (DLC1) and wire clamp from the brackets
     
    Vacuum line from the fuel pressure regulator
     
    Fuel return hose from the pressure regulator
     
    Union bolt and gaskets
     
    Fuel inlet pipe from the fuel rail
     
    Fuel rail with the injectors attached
     



    4 insulators from the four spacers
     
    Fuel injectors from the fuel rail
     
    O-ring and grommet, discard them
     

  6.  

To install:

  1. Install or connect the following:

    New grommets and O-rings on each injector, lubricated with a light coat of gasoline
     
    Fuel injectors, with the electrical connector facing upwards
     
    New insulators and spacers on the intake manifold
     

  2.  
  3. Temporarily install the bolts holding the delivery pipe to the intake manifold.
  4.  
  5. Check that the injectors rotate smoothly.
  6.  
  7. Install or connect the following:

    Tighten the delivery pipe-to-intake manifold bolts to 15 ft. lbs. (21 Nm).
     
    Injector electrical connectors
     
    Fuel inlet pipe with new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm) and the bolt to 14 ft. lbs. (20 Nm).
     
    Fuel return pipe to the fuel pressure regulator
     
    Vacuum line to the pressure regulator
     
    Throttle body
     
    Negative battery cable
     

  8.  

2TR-FE Engine


Click image to see an enlarged view

Fig. Fuel injector and related components-2.7L (2TR-FE) engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the engine undercover subassembly.
  8.  
  9. Drain the engine coolant. Remove the intake air connector.
  10.  
  11. Remove the throttle body motor assembly.
  12.  
  13. Disconnect and plug the fuel line hoses.
  14.  
  15. Remove the fuel pressure pulsation damper assembly.
  16.  
  17. Disconnect the fuel injector electrical connectors. Disconnect the VSV connector. Disconnect the engine wiring harness clamp.
  18.  
  19. Disconnect the air conditioning compressor clutch connector. Disconnect the wire harness clamp. Remove the bolt and then remove the harness clamp bracket.
  20.  
  21. Remove the two bolts and remove the fuel rail together with the fuel injectors.
  22.  
  23. Remove the fuel rail number one spacers. Remove the four injector vibration insulators. Remove the four spacers.
  24.  
  25. Remove the fuel injectors. Discard all gaskets.
  26.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new gaskets and O-rings, as required.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

5vz-FE Engine


Click image to see an enlarged view

Fig. Fuel injector and related components-3.4L engine



Click image to see an enlarged view

Fig. Install new O-rings and grommets on each injector-3.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Depressurize the fuel system.
  4.  
  5. Remove or disconnect the following:

    Air cleaner hose
     
    Upper half of the intake manifold
     
    Fuel pressure regulator
     
    Fuel inlet pipe
     
    Fuel injector electrical connections
     
    Fuel rail with the injectors
     
    Spacers from the intake manifold
     
    Injectors from the delivery pipes
     
    O-rings and grommets, discard them
     

  6.  

To install:

  1. Install or connect the following:

    New grommets and O-rings on each injector, lubricated with a light coat of gasoline
     
    Fuel injector with the electrical connector facing outward
     
    Spacers on the intake manifold
     

  2.  
  3. Temporarily install the bolts to hold the delivery pipes to the intake manifold.
  4.  
  5. Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly.
  6.  
  7. Install or connect the following:

    Fuel injector electrical connectors
     
    Fuel pipe with new gaskets. Tighten the bolts to 25 ft. lbs. (34 Nm) and the delivery pipes-to-intake manifold bolts to 10 ft. lbs. (13 Nm).
     
    Fuel pipe union with new gaskets. Tighten the clamp bolt to 71 inch lbs. (8 Nm).
     
    Fuel pressure regulator
     

  8.  
  9. Inspect the vacuum lines and connections. Look for any loose connections, sharp bends or damage.
  10.  
  11. Install or connect the following:

    Air cleaner
     
    Air cleaner hose
     

  12.  
  13. Start the engine and check for vacuum and fuel leaks.
  14.  

 
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