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Tài liệu hướng dẫn sửa chữa Hệ thống nhiên liệu trên xe 2005 2006 toyota hilux factory service manual fuel system he thong nhien lieu. Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành sửa chữa nhanh chóng, chính xác, hiệu quả
2TR-FE FUEL – FUEL SYSTEM MADE BY VB-SERVICES FU–1 FUEL SYSTEM PRECAUTION PRECAUTION (a) Before working on the fuel system, disconnect the cable from the negative battery terminal (b) Do not work on the fuel system near fire Never smoke during the work (c) Keep rubber and leather parts away from gasoline DISCHARGE FUEL PRESSURE CAUTION: • Before removing fuel system parts, take precautions to prevent gasoline spillage • As some pressure remains in the fuel line even after taking precautions to prevent gasoline spillage, use a shop rag to prevent gasoline splashes when disconnecting the fuel line (a) Disconnect the cable from the negative battery terminal (b) Remove the engine relay block cover (c) Remove the circuit opening relay (d) Connect the cable to the negative battery terminal Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) (e) Start the engine (f) Turn the ignition switch to ON after the engine stops HINT: DTC P0171 (system to lean) may be present (g) Crank the engine again, and check that the engine stops (h) Remove the fuel tank cap, and discharge the pressure in the fuel tank completely (i) Install the circuit opening relay Circuit Opening Relay G037918E01 B000679E04 FUEL SYSTEM (a) When disconnecting the high-pressure fuel line, a large amount of gasoline will splash So take the following precautions (1) Discharge the fuel system pressure (step 2) (2) Disconnect the fuel tank main tube (see page FU-30) (3) Drain the fuel remaining in the fuel tank main tube (4) Cover the disconnected fuel tank main tube (fuel tube joint and fuel tube connector) with a vinyl bag to prevent damage and the intrusion of foreign objects FU FU–2 2TR-FE FUEL – FUEL SYSTEM (b) Take the following precautions when installing the fuel injector (1) Do not reuse the O-ring (2) Do not damage a new O-ring when installing it onto the fuel injector (3) Before installing a new O-ring, apply gasoline or spindle oil NOTICE: Do not use engine oil, gear oil or brake oil CORRECT O-ring WRONG Delivery Pipe A075945E04 Delivery Pipe Injector O-ring Insulator (4) Install the fuel injector into the fuel delivery pipe and cylinder head as illustrated HINT: Apply gasoline or spindle oil to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector Intake Manifold G039405E02 FU Nylon Tube Retainer Fuel Tube Connector O-ring Pipe (c) Take the following precautions when disconnecting the fuel tube connector HINT: The structure of the fuel tube connector is as shown in the illustration (1) Check the fuel tube connector and pipe for dirt and mud before removing the fuel tube connector If dirty, wipe it with a shop rag A098610E07 Retainer Pinch Pull Out (2) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe Pinch A088336E08 (3) If the fuel tube connector and pipe are stuck, pinch the pipe and push and pull the fuel tube connector to release it NOTICE: Never use any tools (4) After disconnecting the fuel tube, check the sealing surface of the pipe for dirt and mud If dirty, wipe it with a shop rag A088337E01 2TR-FE FUEL – FUEL SYSTEM Vinyl Bag FU–3 (5) Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects A088338E02 (d) Take the following precautions when installing the fuel tube connector (1) Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound Push A088339E02 (2) After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them Pull A088340E02 FU FU–8 2TR-FE FUEL – FUEL INJECTOR FUEL INJECTOR 2TR-FE FUEL ENGINE COMPONENTS 8.0 (82, 71 in.*lbf) INTAKE AIR CONNECTOR 8.0 (82, 71 in.*lbf) FU 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft*lbf) : Specified torque A113623E01 FU–9 2TR-FE FUEL – FUEL INJECTOR x2 x2 (92, 80 in.*lbf) (92, 80 in.*lbf) THROTTLE BODY ASSEMBLY FU GASKET WATER BY-PASS HOSE NO WATER BY-PASS HOSE N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A113624E02 FU–10 2TR-FE FUEL – FUEL INJECTOR 8.5(87, 75 in.*lbf) x2 12 (122, 9) FUEL PRESSURE PULSATION DAMPER ASSEMBLY 12 (122, 9) FUEL DELIVERY PIPE SUB-ASSEMBLY WITH FUEL PRESSURE REGULATOR ASSEMBLY FUEL HOSE ٨ FUEL INJECTOR O-RING FU x4 FUEL INJECTOR ASSEMBLY DELIBERY PIPE NO SPACER FUEL HOSE NO.2 x4 ٨INJECTOR VIBRATION x4 INSULATOR x4 x4 SPACER ٨ O-RING N*m (kgf*cm, ft.*lbf) : Specified torque ٨ Non-reusable part A113626E01 2TR-FE FUEL – FUEL PRESSURE REGULATOR FU–19 FUEL PRESSURE REGULATOR REMOVAL DISCHARGE FUEL SYSTEM PRESSURE (See page FU-1) DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE INTAKE AIR CONNECTOR (See page ES452) DISCONNECT NO FUEL HOSE (See page FU-11) REMOVE FUEL PRESSURE REGULATOR (a) Disconnect the throttle with motor body connectors (b) Disconnect the VSV connector (c) Disconnect the engine wire harness clamp (d) Remove the bolt, then remove the harness clamp bracket FU G037907E01 (e) Remove the bolts, then remove the fuel pressure regulator G037908E01 INSTALLATION O-ring G037909E03 INSTALL FUEL PRESSURE REGULATOR ASSEMBLY (a) Apply a light coat of gasoline or spindle oil to the Oring FU–20 2TR-FE FUEL – FUEL PRESSURE REGULATOR (b) Install the fuel pressure regulator with the bolts Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) G037908E01 (c) Install the harness clamp bracket with the bolt Torque: 8.2 N*m (84 kgf*cm, 73 in.*lbf) (d) Connect the engine wire harness clamp (e) Connect the VSV connector (f) Connect the throttle with motor body connectors CONNECT NO FUEL HOSE (See page FU-17) INSTALL INTAKE AIR CONNECTOR (See page ES455) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) CHECK FOR FUEL LEAKAGE (See page FU-7) FU G037907E01 2TR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FU–21 FUEL PRESSURE PULSATION DAMPER REMOVAL DISCHARGE FUEL SYSTEM PRESSURE (See page FU-1) DISCONNECT FUEL HOSE (See page FU-11) REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Remove the bolts, then remove the fuel pressure pulsation damper G037905E01 INSTALLATION O-ring INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Apply a light coat of gasoline or spindle oil to the Oring G037906E01 (b) G037905E01 Install the fuel pressure pulsation damper with the bolts Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) CONNECT FUEL HOSE (See page FU-17) CHECK FOR FUEL LEAKAGE (See page FU-7) FU FU–22 2TR-FE FUEL – FUEL PUMP FUEL PUMP 2TR-FE FUEL ENGINE COMPONENTS FUEL PUMP COVER FUEL TANK VENT HOSE FUEL PUMP CONNECTOR FUEL TANK ASSEMBLY FU FUEL TANK INLET TUBE CLIP PIN FUEL TANK OUTLET TUBE CLIP PIN NO FUEL TANK BAND FUEL PIPE CLAMP FUEL TANK BAND 62 (632, 46) 62 (632, 46) N*m (kgf*cm, ft*lbf) : Specified torque A113599E03 2TR-FE FUEL – FUEL TANK FU–37 (2) Install the checker onto the pipe (h) Tighten the clamp bolt Nylon Tube Fuel Tube Connector CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Connect the fuel tank main tube and return tube (1) Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank main tube and return tube NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work • After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them (b) Install the fuel pipe clamp ADD FUEL CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) CHECK FOR FUEL LEAKAGE (See page FU-7) Retainer O-ring Pipe A098610E08 FU 1GR-FE FUEL – FUEL SYSTEM FU–1 FUEL SYSTEM PRECAUTION PRECAUTION (a) Before working on the fuel system, disconnect the cable from the battery negative terminal (b) Do not work on the fuel system near fire Never smoke during the work (c) Keep rubber and leather parts away from gasoline DISCHARGE FUEL PRESSURE CAUTION: • Before removing fuel system parts, take precautions to prevent gasoline spillage • As some pressure remains in the fuel line even after taking precautions to prevent gasoline spillage, use a shop rag to prevent gasoline splashes when disconnecting the fuel line (a) Disconnect the cable from the battery negative terminal (b) Remove the engine relay block cover (c) Remove the circuit opening relay (d) Connect the cable to the battery negative terminal Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (e) Start the engine (f) Turn the ignition switch to ON after the engine stops HINT: DTC P0171 (system to lean) may be present (g) Crank the engine again and check that the engine stops (h) Remove the fuel tank cap and discharge the pressure in the fuel tank completely (i) Install the circuit opening relay Circuit Opening Relay G036077E01 B000679E04 FUEL SYSTEM (a) When disconnecting the high-pressure fuel line, a large amount of gasoline will splash So take the following precautions (1) Discharge the fuel system pressure (step 2) (2) Disconnect the fuel tank main tube (see page FU-30) (3) Drain the fuel remaining in the fuel tank main tube (4) Cover the disconnected fuel tank main tube (fuel tube joint and fuel tube connector) with a vinyl bag to prevent damage and the intrusion of foreign objects FU FU–2 1GR-FE FUEL – FUEL SYSTEM (b) Take the following precautions when installing the fuel injector (1) Do not reuse the O-ring (2) Do not damage a new O-ring when installing it into the fuel injector (3) Before installing a new O-ring, apply gasoline or spindle oil NOTICE: Do not use engine oil, gear oil or brake oil CORRECT O-ring WRONG Delivery Pipe A075945E04 Delivery Pipe O-ring Intake Manifold Injector (4) Install the fuel injector into the fuel delivery pipe and cylinder head as illustrated NOTICE: Apply gasoline or spindle oil to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector Insulator FU A075911E05 Nylon Tube Fuel Tube Connector Retainer O-ring Pipe (c) Take the following precautions when disconnecting the fuel tube connector (type A) HINT: The structure of the fuel tube connector is as shown in the illustration (1) Check the fuel tube connector and pipe for dirt and mud before removing the fuel tube connector If dirty, wipe it with a shop rag A098610E09 (2) Pinch the retainer as illustrated, and pull the fuel tube connector out of the pipe Retainer Pinch Pull Out Pinch A088336E09 (3) If the fuel tube connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect it NOTICE: Never use any tools (4) After removing the fuel tube, check the sealing surface of the pipe for dirt and mud If dirty, wipe it with a shop rag A088337E01 1GR-FE FUEL – FUEL SYSTEM Vinyl Bag FU–3 (5) Cover the disconnected fuel tube connector and pipe with a vinyl bag to prevent damage and the intrusion of foreign objects A088338E02 (d) Take the following precautions when installing the fuel tube connector (type A) (1) Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound Push FU A088339E03 (2) After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them Pull A088340E02 FU–9 1GR-FE FUEL – FUEL INJECTOR FUEL INJECTOR 1GR-FE FUEL ENGINE COMPONENTS 7.5 (76, 66 in.*lbf) 7.5 (76, 66 in.*lbf) V-BANK COVER FU VACUUM HOSE 8.0 (82, 71 in.*lbf) AIR CLEANER ASSEMBLY 8.0 (82, 71 in.*lbf) NO.2 VENTILATION HOSE MASS AIR FLOW METER CONNECTOR N*m (kgf*cm, ft*lbf) : Specified torque A113544E01 FU–10 1GR-FE FUEL – FUEL INJECTOR NO.2 SURGE TANK STAY HEATER WATER INLET HOSE A 21 (214, 16) 28 (286, 21) VSV CONNECTOR HEATER WATER OUTLET HOSE A FUEL VAPOR FEED HOSE ASSEMBLY ENGINE WIRE 21 (214, 16) VSV CONNECTOR NO.1 SURGE TANK STAY INTAKE AIR SURGE TANK FU THROTTLE BODY BRACKET GASKET 21 (214, 16) NO.4 WATER BY-PASS HOSE THROTTLE MOTOR CONNECTOR NO.5 WATER BY-PASS HOSE NO.2 FUEL PIPE CLAMP NO.1 VANTILATION HOSE NO.1 FUEL PIPE SUB-ASSEMBLY NO.2 FUEL PIPE SUB-ASSEMBLY x6 15 (153, 11) FUEL DELIVERY PIPE SUB-ASSEMBLY NO.2 FUEL PIPE SUB-ASSEMBLY FUEL INJECTOR CONNECTOR INJECTOR VIBRATION INSULATOR O-RING FUEL INJECTOR ASSEMBLY N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A113545E01 1GR-FE FUEL – FUEL PRESSURE REGULATOR FU–19 FUEL PRESSURE REGULATOR REMOVAL A075657E01 DISCHARGE FUEL SYSTEM PRESSURE (See page FU-1) DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE V-BANK COVER (See page ES-414) REMOVE AIR CLEANER ASSEMBLY (See page ES415) DISCONNECT NO.2 FUEL PIPE SUB-ASSEMBLY (See page FU-13) REMOVE FUEL PRESSURE REGULATOR ASSEMBLY (a) Remove the bolts, then remove the fuel pressure regulator (b) Remove the vacuum hose FU FU–20 1GR-FE FUEL – FUEL PRESSURE REGULATOR INSTALLATION FU INSTALL FUEL PRESSURE REGULATOR ASSEMBLY (a) Install the vacuum hose (b) Apply a light coat of spindle oil or gasoline to a new O-ring and install it onto the fuel pressure regulator (c) Install the fuel pressure regulator with the bolts Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) CONNECT NO.2 FUEL PIPE SUB-ASSEMBLY (See page FU-17) INSTALL AIR CLEANER ASSEMBLY (See page ES416) INSTALL V-BANK COVER (See page ES-416) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) CHECK FOR FUEL LEAKAGE FU–20 1GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FUEL PRESSURE PULSATION DAMPER REMOVAL Clip A078644E03 FU DISCHARGE FUEL SYSTEM PRESSURE (See page FU-1) REMOVE V-BANK COVER (See page ES-414) REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Remove the clip (b) Pull the fuel pressure pulsation damper out of the fuel delivery pipe 1GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FU–21 INSTALLATION INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Apply a light coat of spindle oil or gasoline to a new O-ring and install it onto the fuel pressure pulsation damper (b) Install the fuel pressure pulsation damper onto the fuel delivery pipe (c) Install the clip INSTALL V-BANK COVER (See page ES-416) CHECK FOR FUEL LEAKAGE FU FU–21 1GR-FE FUEL – FUEL PUMP FUEL PUMP 1GR-FE FUEL ENGINE COMPONENTS FUEL TANK VENT HOSE FUEL PUMP CONNECTOR FUEL PUMP COVER FUEL TANK ASSEMBLY FUEL TANK INLET TUBE CLIP PIN CLIP FUEL PIPE CLAMP NO FUEL TANK BAND FUEL TANK OUTLET TUBE CLIP PIN STANDARD: PIN OFF ROAD PACKAGE: PIN STANDARD: FUEL TANK BAND CLIP 62 (632, 46) NO FUEL TANK BAND 62 (632, 46) FUEL TANK BAND 62 (632, 46) 62 (632, 46) NO FUEL PROTECTOR SUB-ASSEMBLY x4 N*m (kgf*cm, ft*lbf) : Specified torque 20 (204, 15) A113559E03 FU FU–22 1GR-FE FUEL – FUEL PUMP FUEL TANK INLET TUBE FUEL TANK OUTLET TUBE RETAINER JOINT CLIIP JOINT CLIIP FU FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY FUEL SENDER GAUGE O-RING GASKET O-RING FUEL PRESSURE REGULATOR FUEL PUMP ASSEMBLY FUEL PUMP FILTER NO FUEL SUB-TANK FUEL TANK ASSEMBLY Non-reusable part A113561E01 1GR-FE FUEL – FUEL PUMP RESISTOR FU–27 FUEL PUMP RESISTOR INSPECTION Ohmmeter G036122E01 INSPECT FUEL PUMP RESISTER (a) Check the resistance (1) Using an ohmmeter, measure the resistance between the terminals Resistance: 0.71 to 0.75 Ω If the result is not as specified, replace the fuel pump resistor FU FU–28 1GR-FE FUEL – FUEL TANK FUEL TANK 1GR-FE FUEL ENGINE COMPONENTS FUEL TANK VENT HOSE FUEL PUMP CONNECTOR FUEL PUMP COVER FUEL TANK ASSEMBLY FUEL TANK INLET TUBE CLIP PIN CLIP FUEL PIPE CLAMP FU NO FUEL TANK BAND FUEL TANK OUTLET TUBE CLIP PIN STANDARD: PIN OFF ROAD PACKAGE: PIN STANDARD: FUEL TANK BAND CLIP 62 (632, 46) NO FUEL TANK BAND 62 (632, 46) FUEL TANK BAND 62 (632, 46) 62 (632, 46) NO FUEL PROTECTOR SUB-ASSEMBLY x4 N*m (kgf*cm, ft*lbf) : Specified torque 20 (204, 15) A113559E03 FU–29 1GR-FE FUEL – FUEL TANK FUEL TANK INLET TUBE FUEL TANK OUTLET TUBE RETAINER JOINT CLIP JOINT CLIP FU FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY GASKET NO FUEL TANK PROTECTOR x4 FUEL TANK TO FILLER PIPE HOSE CLIP FUEL TANK Non-reusable part N*m (kgf*cm, ft*lbf) : Specified torque A113560E01