FU–8 1GR-FE FUEL – FUEL INJECTOR

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(See page FU-1)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. DRAIN ENGINE COOLANT (See page CO-3)
4. REMOVE V-BANK COVER (See page ES-393)
5. DISCONNECT NO. 2 VENTILATION HOSE
(a) Disconnect the No. 2 ventilation hose.
6. REMOVE AIR CLEANER ASSEMBLY (See page ES-
393)

A075594

FU 7. REMOVE INTAKE AIR SURGE TANK

(a) Disconnect the No. 5 water by-pass hose.

A075597E01

(b) Disconnect the No. 4 water by-pass hose.

A075598E01

(c) Disconnect the fuel vapor feed hose.

A075644E01
 1GR-FE FUEL – FUEL INJECTOR FU–9

(d) Disconnect the ventilation hose.

A075645E01

(e) Disconnect the 2 VSV connectors.

(f) Disconnect the throttle motor connector.
(g) Remove the 3 wire harness clamps and hose
clamp.

FU

A075646E01

(h) Remove the 3 upper bolts which are used to secure

the 2 surge tank stays and throttle body bracket.

A075647E01

(i) Using an 8 mm socket hexagon wrench, remove the

4 bolts.
(j) Remove the 2 nuts, then remove the intake air
surge tank and gasket.

A075648E02
 FU–10 1GR-FE FUEL – FUEL INJECTOR

8. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp.
(b) Pinch the tube connector, and then pull the fuel pipe
out of the pipe as shown in the illustration.
2 Pull
NOTICE:
1 Pinch 1 Pinch • Remove any dirt and foreign objects from the
fuel tube connector before performing this
work.
• Do not allow any scratches or foreign objects
on the parts when disconnecting, as the fuel
tube connector has the O-ring that seals the
pipe.
• Perform this work by hand. Do not use any
Tube Connector
Nylon Tube tools.
• Do not forcibly bend, twist or turn the nylon
tube.
• Protect the disconnected part by covering it
with a vinyl bag after disconnecting the fuel
O-ring Pipe tube.
• If the fuel tube connector and pipe are stuck,
FU A121823E01 push and pull to release them.

9. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp.
(b) Pinch the tube connector, and then pull the fuel pipe
2 Pull out of the pipe as shown in the illustration.
NOTICE:
• Remove any dirt and foreign objects from the
fuel tube connector before performing this
work.
• Do not allow any scratches or foreign objects
1 Pinch
on the parts when disconnecting, as the fuel
tube connector has the O-ring that seals the
pipe.
Tube Connector • Perform this work by hand. Do not use any
Nylon Tube tools.
• Do not forcibly bend, twist or turn the nylon
tube.
• Protect the disconnected part by covering it
with a vinyl bag after disconnecting the fuel
O-ring Pipe tube.
• If the fuel tube connector and pipe are stuck,
A121824E01 push and pull to release them.
 1GR-FE FUEL – FUEL INJECTOR FU–11

10. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Disconnect the 6 fuel injector connectors.
(b) Remove the 6 bolts and fuel delivery pipe together
with the 6 fuel injectors.
NOTICE:
Be careful not to drop the injectors when
removing the fuel delivery pipe.

A075652E01

11. REMOVE FUEL INJECTOR

(a) Pull the 6 injectors out of the delivery pipe.

Delivery Pipe FU
Injector

A075653E05

INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
Ohmmeter
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard
Tester Connection Specified Condition
1-2 11.6 to 12.4 Ω at 20°C (68°F)
A095332E03
If the result is not as specified, replace the fuel
injector.
(b) Check the injection volume.
Pressure Fuel Tube
Regulator
NOTICE:
Connector
• Perform the test in a well-ventilated area and
SST watch out for flames.
• Handle the fuel tube connector carefully.
SST (1) Prepare a new fuel tube.
SST HINT:
Part No. 23801-31070
Injector
A075912E01
 FU–12 1GR-FE FUEL – FUEL INJECTOR

(2) Using a cutter knife, cut the fuel tube protector.

Fuel Tube Connector Tear the protector by hand, then remove the
fuel tube connector.
NOTICE:
If the protector is cut too deeply with the
cutter, the O-ring of the fuel tube connector
will be damaged.

A062159E01

(3) Install the fuel tube connector into SST (hose),

then connect the tube connector to the fuel
pipe.
SST 09268-41047 (95336-08070)
SST (Hose)
CAUTION:
Connect the fuel tube connector (quick
type) after observing the precautions.
Fuel Tube Connector
(4) Remove the pressure regulator (See page FU-
22).
FU B012947E04 (5) Install the O-ring onto the fuel inlet of the
pressure regulator.
(6) Connect SST (hose) to the fuel inlet of the
Pressure
Regulator
pressure regulator with another SST (union)
and the 2 bolts.
SST
SST 09268-41047 (95336-08070, 09268-
(Hose)
41091)
SST Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
(Union) (7) Connect the fuel return hose to the fuel outlet of
the pressure regulator.
Fuel Return Hose
A076630E01

(8) Install a new O-ring onto the injector.

O-Ring (9) Connect SST (adaptor and hose) to the injector
SST
and hold the injector and union with SST
(clamp).
SST 09268-41047 (95336-08070), 09268-
SST SST 41140, 09268-41400
(Adapter) (Clamp) (10) Set the injector in a graduated cylinder.
CAUTION:
Vinyl Tube Install a suitable vinyl tube onto the injector
A075914E03 to prevent gasoline splashes.

(11) Connect the intelligent tester to the DLC3.

Intelligent Tester
(12) Turn the ignition switch to ON.
(13) Turn the intelligent tester ON.
(14) Select the following menu items: DIAGNOSIS /
ENHANCED OBD ll / ACTIVE TEST / FUEL
CAN VIM PUMP / SPD / ON.
(15) Install SST onto the fuel injector.
SST 09842-30080
DLC3 A094482E02
 1GR-FE FUEL – FUEL INJECTOR FU–13

(16) Connect SST to the battery, then measure the

injection volume for 15 seconds. Perform the
inspection 2 or 3 times, then calculate the
average.
Standard:
SST
Injection Volume Difference Between Each Fuel
(Wire) Injector
Connect
76 to 91 cm3 (4.6 to 5.5 cu in.) per 15 15 cm3 (0.9 cu in.) or less
seconds
A075915E04
NOTICE:
Always do the switching at the battery side.
If the result is not as specified, replace the fuel
injector.
(c) Check the fuel leakage.
(1) When checking the injection volume, remove
SST from the battery. Inspect the fuel leakage
from the fuel injector.
SST 09842-30080
Standard:
1 drop or less every 12 minutes. FU
If the result is not as specified, replace the fuel
injector.
A075916

INSTALLATION
1. INSTALL FUEL INJECTOR
New Insulator (a) Install a new insulator onto each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to a new
O-ring and install it onto each fuel injector.

New O-ring
A075654E06

(c) While turning the fuel injector left and right, install it
onto the fuel delivery pipe.
(d) Position the fuel injector connector facing outward.

Connector

Turn

Push
A075655E04
 FU–14 1GR-FE FUEL – FUEL INJECTOR

2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Place the fuel delivery pipe together with the 6 fuel
injectors on the intake manifold.
(b) Provisionally install the 6 bolts, which are used to
hold the fuel delivery pipe, onto the intake manifold.
(c) Check that the fuel injectors rotate smoothly.
Turn HINT:
Connector If the fuel injectors do not rotate smoothly, replace
the O-ring.
A075656E03 (d) Position the fuel injector connector facing outward.
(e) Tighten the 6 bolts, which are used to hold the fuel
delivery pipe, to the intake manifold.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
(f) Connect the 6 fuel injector connectors.
3. CONNECT FUEL PIPE SUB-ASSEMBLY
(a) Push the tube connector into the pipe until the tube
connector makes a "click" sound.
NOTICE:
• Check if there is any damage or foreign
objects on the connected part of the fuel pipe.
FU • After connecting, check that the pipe and
connector are securely connected by pulling
them.
(b) Install the fuel pipe clamp.
4. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) Push the tube connector into the pipe until the tube
connector makes a "click" sound.
NOTICE:
• Check if there is any damage or foreign
objects on the connected part of the fuel pipe.
• After connecting, check that the pipe and
connector are securely connected by pulling
them.
(b) Install the fuel pipe clamp.
5. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket and the intake air surge tank
with the 2 nuts.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
(b) Using an 8 mm socket hexagon wrench, install the 4
bolts.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)

A075648E02
 1GR-FE FUEL – FUEL INJECTOR FU–15

(c) Install the 3 upper bolts which are used to secure

the 2 surge tank stays and throttle body bracket.
Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)

A075647E01

(d) Install the 3 wire harness clamps and hose clamp.

(e) Connect the throttle motor connector.
(f) Connect the 2 VSV connectors.

FU

A075646E01

(g) Connect the ventilation hose.

A075645E01

(h) Connect the fuel vapor feed hose.

A075644E01
 FU–16 1GR-FE FUEL – FUEL INJECTOR

(i) Connect the No. 4 water by-pass hose.

A075598E01

(j) Connect the No. 5 water by-pass hose.

6. INSTALL AIR CLEANER ASSEMBLY (See page ES-
395)

FU A075597E01

7. CONNECT NO. 2 VENTILATION HOSE

(a) Connect the No. 2 ventilation hose.
8. INSTALL V-BANK COVER (See page ES-396)
9. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
10. ADD ENGINE COOLANT (See page CO-3)
11. CHECK FOR ENGINE COOLANT LEAKAGE (See
A075594E01 page CO-4)
12. CHECK FOR FUEL LEAK
1GR-FE FUEL – FUEL PRESSURE REGULATOR FU–19

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(See page FU-1)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE V-BANK COVER (See page ES-393)
4. DISCONNECT NO. 2 VENTILATION HOSE
(a) Disconnect the No. 2 ventilation hose.
5. REMOVE AIR CLEANER ASSEMBLY (See page ES-
393)
6. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
(See page FU-10)

A075594

7. REMOVE FUEL PRESSURE REGULATOR

ASSEMBLY
(a) Remove the 2 bolts, then remove the fuel pressure
FU
regulator.
(b) Remove the vacuum hose.

A075657E01

INSTALLATION
1. 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 2 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
A075657E01
3. INSTALL AIR CLEANER ASSEMBLY (See page ES-
395)
4. CONNECT NO. 2 VENTILATION HOSE
(a) Connect the No. 2 ventilation hose.
5. INSTALL V-BANK COVER (See page ES-396)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
7. CHECK FOR FUEL LEAK
A075594
 FU–22 1GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(See page FU-1)
2. REMOVE V-BANK COVER (See page ES-393)
3. REMOVE FUEL PRESSURE PULSATION DAMPER
Clip ASSEMBLY
(a) Remove the clip.
(b) Pull the fuel pressure pulsation damper out of the
fuel delivery pipe.

A078644E03

FU
1GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FU–23

INSTALLATION
1. 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.
2. INSTALL V-BANK COVER (See page ES-396)
3. CHECK FOR FUEL LEAK

FU
 1GR-FE FUEL – FUEL PUMP FU–25

3. REMOVE FUEL PUMP FILTER

(a) Using a small screwdriver, pry out the clip.
(b) Pull out the fuel pump filter from the fuel pump.

A076669

INSPECTION
1. INSPECT FUEL PUMP
(a) Inspect the fuel pump resistance.
(1) Using an ohmmeter, measure the resistance
between terminals 4 and 5.
Standard resistance:
0.2 - 3.0 Ω at 20°C (68°F)
(b) Inspect fuel pump operation.
(1) Apply the battery voltage to both terminals.
A032859E02
Check that the pump operates. FU
NOTICE:
• These tests must be done quickly (within
10 seconds) to prevent the coil from
burning out.
• Keep fuel pump as far away from the
battery as possible.
• Always do the switching at the battery
side.
 FU–26 1GR-FE FUEL – FUEL PUMP

REASSEMBLY
1. INSTALL FUEL PUMP FILTER
(a) Install the fuel pump filter with a new clip.
2. INSTALL FUEL PUMP ASSEMBLY WITH FILTER
(a) Install a fuel pump spacer to the fuel pump.
Apply a
light coat of (b) Apply a light coat of gasoline to a new O-ring, and
gasoline install it to the fuel pump.
(c) Apply a light coat of gasoline to the O-ring again,
and install the fuel pump to the fuel filter.

A076675E01

(d) Install the sub tank.

(1) Apply a light coat of gasoline to a new O-ring,
Apply a and install it to the fuel suction tube assembly.
light coat of (2) Apply a light coat of gasoline to the O-ring
gasoline again, and install the sub tank to the fuel filter.
FU

A076672E01

3. INSTALL FUEL SENDER GAGE ASSEMBLY

(a) Lock the fuel sender gage.
(b) Connect the fuel sender gage connector.

A067105
1GR-FE FUEL – FUEL PUMP FU–27

INSTALLATION
1. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE
ASSEMBLY (See page FU-33)

FU
 1GR-FE FUEL – FUEL SYSTEM FU–1

FUEL SYSTEM
PRECAUTION
1. PRECAUTION
(a) Before starting on the work for the fuel system
inspection and repair, disconnect the negative (-)
terminal cable from the battery.
(b) Do not smoke or work near fire when handling the
fuel system.
(c) Keep gasoline away from rubber or leather parts.
2. WORK FOR PREVENT GASOLINE FROM SPILLING
OUT
CAUTION:
• Take precaution for preventing gasoline from
spilling out before removing the fuel system
parts.
• As there is the remained pressure in the fuel line
after working for prevent gasoline from spilling
out, prevent it from splashing inside the vehicle
compartment by covering them with a shop rag. FU
(a) Remove the circuit opening relay from the engine
room relay block.
(b) Start the engine. After the engine stopped, turn the
ignition switch OFF.
HINT:
There is a case that DTC P0171 (system to lean) is
output.
(c) Check that the engine does not start.
(d) Remove the fuel tank cap, and let the air out of the
C/OPN Relay A067118E01 fuel tank.
(e) Disconnect the negative (-) terminal cable from the
battery.
(f) Reinstall the circuit opening relay.
3. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a
large amount of gasoline will spill out, so observe
these procedures.
(1) Disconnect the fuel pump tube (See page FU-
29).
(2) Drain the fuel remained inside the fuel pump
tube.
(3) In order to prevent the disconnected fuel pump
B000679 tube from damaging and foreign objects from
being mixed into, cover them with a vinyl bag.
(4) Put a container under the connection.
 FU–2 1GR-FE FUEL – FUEL SYSTEM

(b) Observe these precautions when removing and

CORRECT installing the injectors.
(1) Never reuse the O-ring.
(2) When placing a new O-ring on the injector, do
not damage it.
O-ring (3) Coat the new O-rings with spindle oil or gasoline
WRONG
before installing. Do not use engine oil, gear oil
or brake oil.
Delivery Pipe
A075945E04

(c) Install the injector to the delivery pipe and lower

Delivery Pipe intake manifold as shown in the illustration.
O-ring NOTICE:
Intake Before installing the injector, must apply spindle
Manifold oil or gasoline on the place where a delivery
Injector pipe or cylinder head contacts the O-ring of the
injector.
Insulator

FU A075911E05

(d) Observe these precautions when disconnecting the

Quick
fuel tube connector (Quick type A):
Type A
(1) Remove the fuel pipe clamp No. 1.
(2) Check that there is no dirt like mud on the pipe
and around the connector before disconnecting
Fuel Pipe them. Clean them if necessary.
Clamp No. 1 (3) Disconnect them by hand.

A060083E19

(4) When the connector and the pipe are stuck,

Quick Type A pinch the fuel pipe with fingers and push the fuel
Push tube connector to the fuel pipe by pressing the
release buttons, then pull the connector out from
the pipe.
(5) Inspect that there is no dirt or the like on the seal
surface of the disconnected pipe. Clean it away
if necessary.
Pull Push (6) In order to prevent the disconnected pipe and
B016533E03 connector from damaging and foreign objects
from being mixed into, cover them with a vinyl
bag.
 1GR-FE FUEL – FUEL SYSTEM FU–3

(e) Observe these precautions when connecting the

Quick Type A fuel tube connector (Quick Type A):
(1) Check that there is no damage or foreign objects
in the connected part of the pipe.
(2) Match the axis of the connector with the axis of
the pipe, and push into the connector until the
connector makes a "click" sound. In case that
the connection is tight, apply a little amount of
Push fresh engine oil on the tip of the pipe.
B016534E03

(3) After having finished the connection, check if the

Quick Type A pipe and the connector are securely connected
by pulling them.
(4) Check for any fuel leak.
(f) Observe these precautions when disconnecting the
fuel tube connector (Quick type B):
(1) Check if there is any dirt like mud on the pipe
and around the connector before disconnecting
Pull them. Clean the dirt away if necessary.
B016535E03 (2) Disconnect them by your hands. FU
(3) When the connector and the pipe are stuck,
Quick Type B
push and pull the connector to free to disconnect
and pull it out. Do not use any tool at this time.
(4) Inspect if there is any dirt or the like on the seal
Pull
surface of the disconnected pipe. Clean it away
if necessary.
(5) Prevent the disconnected pipe and connector
from damaging and foreign objects from being
Push mixed into by covering them with a vinyl bag.
B002045E01

(g) Observe these precautions when connecting the

Quick Type B
fuel tube connector (Quick type B):
Push (1) Match the axis of the connector with the axis of
the pipe, and push in the connector until the
connector makes a "click" sound. In case that
the connection is tight, apply a little amount of
new engine oil on the tip of the pipe.

B002046E01

(2) After having finished the connection, check if the

Quick Type B
pipe and the connector are securely connected
by pulling them.
Pull (3) Check for fuel leakage.
(h) Observe these precautions when handling nylon
tube.
CAUTION:
• Be careful not to turn the connection part of
the nylon tube and the quick connector when
B002077E01 connecting them.
• Do not kink the nylon tube.
 FU–4 1GR-FE FUEL – FUEL SYSTEM

• Do not remove the EPDM protector on the

outside of the nylon tube.
• Do not close the piping with the nylon tube by
bending it.
4. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after doing
maintenance to the fuel system (See page FU-4).

FU
 1GR-FE FUEL – FUEL SYSTEM FU–5

ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the intelligent tester
(1) Connect the intelligent tester to the DLC3.
(2) Turn the ignition switch ON and intelligent
tester main switch ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the
intelligent tester.
(4) Please refer to the intelligent tester operator's
manual for further details.
(b) When not using the intelligent tester
(1) Remove the circuit opening relay.
(2) Using a service wire, connect terminals FP and
+B of the relay block.
NOTICE:
Pay due attention to the terminal
connecting position to avoid a malfunction.
(3) Turn the ignition switch ON, and check that the FU
fuel pump operates.
NOTICE:
Do not start the engine.
(c) Check that there are no fuel leaks after doing
FP +B
maintenance to the fuel system.
(d) Turn the ignition switch OFF.
(e) Disconnect the intelligent tester from the DLC3.
A067117E01

2. CHECK FUEL PRESSURE

Fuel Tube Connector (a) Prepare for inspection.
(1) Prepare a new fuel tube, and take out the fuel
tube connector from the tube.
HINT:
Part No. 23801-31070
(b) Prevent gasoline from spilling out (See page FU-1).
(c) Disconnect the EFI fuel pipe clamp (See page FU-
1).
A062159E01 (d) Disconnect the fuel pipe No. 1 from the fuel main
tube.
 FU–6 1GR-FE FUEL – FUEL SYSTEM

(e) Install SST (pressure gauge) as shown in the

SST (Clip) illustration by using the SSTs and a fuel tube
connector.
SST (Gauge)
SST 09268-31011 (90467-13001, 95336-08070),
09268-45014 (09268-41200, 09268-41220,
09268-41250, 90467-13001)
SST (T-joint) (f) Wipe off any splattered gasoline.
(g) Start the engine.
Fuel Tube (h) Measure the fuel pressure at idle.
Fuel pressure:
SST (Hose) 281 - 287 kPa (2.87 - 2.93 kgf/cm2, 40.8 - 41.7
psi)
(i) Stop the engine.
SST (j) Check that the fuel pressure remains as specified
for 5 minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm2, 21 psi) or more
If pressure is not as specified, check the fuel pump,
SST (Hose) Fuel Tube Connector pressure regulator and/or injectors.
(k) After checking the fuel pressure, disconnect the
FU A065093E01
negative (-) terminal cable from the battery carefully,
remove the SST and fuel tube connector to prevent
gasoline from the splashing.
(l) Reconnect the fuel tube to the fuel main tube.
(m) Install the EFI fuel pipe clamp.
(n) Check for fuel leak.
 FU–6 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

A113544E04
 1GR-FE FUEL – FUEL INJECTOR FU–7

HEATER WATER INLET NO. 2 SURGE TANK STAY

HOSE A
21 (214, 16)

28 (286, 21)

HEATER WATER VSV CONNECTOR

OUTLET HOSE A
FUEL VAPOR FEED
HOSE ASSEMBLY

ENGINE WIRE
21 (214, 16)

VSV CONNECTOR
NO. 1 SURGE TANK STAY
INTAKE AIR SURGE TANK

THROTTLE BODY
BRACKET
GASKET FU
21 (214, 16)
NO. 4 WATER BY-PASS HOSE
THROTTLE MOTOR CONNECTOR
NO. 5 WATER BY-PASS HOSE
NO. 1 FUEL PIPE CLAMP
NO. 1 VANTILATION HOSE
NO. 1 FUEL PIPE SUB-ASSEMBLY

NO. 2 FUEL PIPE CLAMP 15 (153, 11)

x6

FUEL DELIVERY PIPE

SUB-ASSEMBLY
NO. 2 FUEL PIPE SUB-ASSEMBLY

FUEL INJECTOR CONNECTOR O-RING

INJECTOR VIBRATION FUEL INJECTOR ASSEMBLY

INSULATOR

N*m (kgf*cm, ft*lbf) : Specified torque

Non-reusable part

A113545E03
 1GR-FE FUEL – FUEL PRESSURE REGULATOR FU–17

FUEL PRESSURE REGULATOR

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

A113544E05
 FU–18 1GR-FE FUEL – FUEL PRESSURE REGULATOR

FU

NO. 2 FUEL PIPE CLAMP

NO. 2 FUEL PIPE SUB-ASSEMBLY

9.0 (92, 80 in.*lbf)

9.0 (92, 80 in.*lbf)

N*m (kgf*cm, ft*lbf) : Specified torque

A113545E04
 FU–20 1GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER

FUEL PRESSURE PULSATION DAMPER

1GR-FE FUEL
ENGINE

COMPONENTS

7.5 (76, 66 in.*lbf)

7.5 (76, 66 in.*lbf)

V-BANK COVER

FU

N*m (kgf*cm, ft.*lbf) : Specified torque

A113544E06
 1GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FU–21

FU

FUEL PRESSURE PULSATION

DAMPER ASSEMBLY

A113545E05
 1GR-FE FUEL – FUEL PUMP FU–23

FUEL PUMP
1GR-FE FUEL
ENGINE

COMPONENTS

FUEL FILTER FU

O-RING
O-RING

FUEL PUMP SPACER

FUEL PUMP

FUEL PUMP FILTER

FUEL SENDER GAGE

ASSEMBLY CLIP

SUB TANK

Non-reusable part
A151290E03
 FU–24 1GR-FE FUEL – FUEL PUMP

REMOVAL
1. REMOVE FUEL SUCTION WITH PUMP & GAGE
TUBE ASSEMBLY (See page FU-31)
DISASSEMBLY
1. REMOVE FUEL SENDER GAGE ASSEMBLY
(a) Disconnect the fuel sender gage connector.
(b) Unlock the fuel sender gage, and slide it to remove.

A067105

2. REMOVE FUEL PUMP ASSEMBLY WITH FILTER

(a) Using a screwdriver, disconnect the 4 snap-claws
from the claw holes, and remove the sub tank.
NOTICE:
Do not damage the sub tank.
FU

A076666

(b) Disconnect the fuel pump connector.

A076667

(c) Using a small screwdriver, disconnect the 4 claws

from the claw holes, and remove the fuel pump with
filter.
(d) Remove the fuel pump O-ring from the fuel pump.
(e) Remove the fuel pump spacer from the fuel pump.

A076668
 1GR-FE FUEL – FUEL PUMP RESISTOR FU–27

Ohmmeter
FUEL PUMP RESISTOR
INSPECTION
1. INSPECT FUEL PUMP RESISTOR
(a) Inspect the fuel pump resistor resistance.
(1) Using an ohmmeter, measure the resistance
between terminal.
Standard resistance:
A072544E01 0.70 - 0.76 Ω at 20°C (68°F)

FU
 1GR-FE FUEL – FUEL PUMP RESISTOR FU–27

Ohmmeter
FUEL PUMP RESISTOR
INSPECTION
1. INSPECT FUEL PUMP RESISTOR
(a) Inspect the fuel pump resistor resistance.
(1) Using an ohmmeter, measure the resistance
between terminal.
Standard resistance:
A072544E01 0.70 - 0.76 Ω at 20°C (68°F)

FU
 FU–28 1GR-FE FUEL – FUEL TANK

FUEL TANK
1GR-FE FUEL
ENGINE

COMPONENTS

REAR FLOOR SERVICE HOLE COVER

RETAINER
FUEL TANK MAIN TUBE

FUEL TANK RETURN TUBE FUEL TANK BREATHER

TUBE SUB-ASSEMBLY

FU GASKET
FUEL SUCTION WITH PUMP
& GAGE TUBE ASSEMBLY FUEL TANK TO FILLER
PIPE HOSE

FUEL TANK ASSEMBLY

PIN

CLIP FUEL TANK BAND

CLIP PIN

FUEL TANK BAND 40 (408, 30)

40 (408, 30)
20 (204, 15)
20 (204, 15)

NO. 1 FUEL TANK PROTECTOR

SUB-ASSEMBLY

20 (204, 15)
N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
A151292E01
 1GR-FE FUEL – FUEL TANK FU–29

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
(See page FU-1)
2. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Hold the rear No. 1 seat assembly LH.
(b) Hold the rear No. 1 seat assembly RH.
(c) Remove a tear-off floor mat.
(d) Remove the 3 screws from the rear floor service
hole cover.
(e) Disconnect the connector.

A133777

3. REMOVE FUEL TANK TO FILLER PIPE HOSE

(a) Disconnect the fuel-tank-to-filler-pipe hose from the
fuel filler pipe.
4. DRAIN FUEL
5. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-
FU
ASSEMBLY
(a) Set a mission jack to the fuel tank protector.
(b) Remove the 6 bolts and the fuel tank protector.
A067088

6. DISCONNECT FUEL TANK MAIN TUBE AND FUEL

TANK RETURN TUBE
(a) Pinch the tabs of the retainer to remove the lock
claws and pull out the 2 fuel tank tubes.
NOTICE:
• Check that there is no dirt or mud around the
quick connector before this work, because
the quick connector has an O-ring which
seals the pipe and the connector. Clean the
connector if necessary.
• Do not use any tool in this work.
• Do not bend or twist the nylon tube.
Nylon Tube • To protect the tube, cover it with a vinyl bag
after checking.
Retainer • When connector and the pipe are stuck, turn
the retainer carefully to free and then
disconnect the fuel tank tube.

Pipe
O-ring
A139367E01
 FU–30 1GR-FE FUEL – FUEL TANK

7. DISCONNECT FUEL TANK BREATHER TUBE SUB-

ASSEMBLY
(a) Pinch a tab of the retainer to remove the lock claws
and pull out the fuel tank tube.
NOTICE:
• Check that there is no dirt or mud around the
quick connector before this work, because
the quick connector has an O-ring which
seals the pipe and the connector. Clean the
connector if necessary.
• Do not use any tool in this work.
• Do not bend or twist the nylon tube by force.
• To protect the tube, cover it with a vinyl bag
Nylon Tube Retainer
after checking.
• When connector and the pipe are stuck, turn
the retainer carefully to free and then
disconnect the tube.

O-ring Pipe

FU A139368E01

8. DISCONNECT FUEL TANK VENT HOSE

Push (a) Disconnect the fuel tank breather tube from the fuel
tank.
Pinch
(1) Push the connector deep inside.
(2) Pinch portion A, as shown in the illustration.
(3) Pull out the connector.
A
Pinch 9. REMOVE FUEL TANK ASSEMBLY
(a) Set a mission jack to the fuel tank.
A (b) Remove the 2 bolts, 2 fuel tank bands and fuel tank.
A067090E01

10. REMOVE FUEL TANK CUSHION

 1GR-FE FUEL – FUEL TANK FU–31

11. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK

RETURN TUBE
(a) Remove the 2 tubes joint clips, and pull out the 2
fuel tank tubes.
NOTICE:
• Check that there is no dirt or mud around the
quick connector before this work, because
the quick connector has an O-ring which
seals the pipe and the connector. Clean the
connector if necessary.
• Do not use any tool in this work.
• Do not bend or twist the nylon tube by force.
• After disconnecting, cover the fuel tube joint
with a vinyl bag.
• When the fuel tube joint and fuel suction plate
are stuck, turn the fuel tank main tube
Fuel Tube Joint Nylon Tube carefully to free and then disconnect it.
Likewise, disconnect the fuel tank return
tube.
12. REMOVE FUEL SUCTION WITH PUMP & GAGE
TUBE ASSEMBLY FU
O-ring
Tube Joint Clip NOTICE:
Protect a connector and tube joint with a masking
tape or something in order to prevent sticking
Fuel Suction Plate
foreign objects onto them, and clean dirt and foreign
A139373E01
objects from the fuel suction tube assembly before
removing it.
(a) Using a SST, loosen the retainer.
SST 09808-14020 (09808-01410, 09808-01420,
SST 09808-01430)
HINT:
A rib on the retainer can be fitted into a tip of the
SST.
(b) Remove the retainer.
(c) Pull out the fuel suction tube assembly.
Rib NOTICE:
A072554E01 Be careful not to bend the arm of the sender
gage.
(d) Remove the gasket from the fuel tank.
 FU–32 1GR-FE FUEL – FUEL TANK

13. REMOVE FUEL TANK BREATHER TUBE SUB-

ASSEMBLY
(a) Pinch the tab of the retainer to remove the lock
claws and pull out the fuel tank breather tube.
NOTICE:
• Check that there is no dirt or mud around the
quick connector before this work, because
the quick connector has an O-ring which
seals the pipe and the connector. Clean the
connector if necessary.
• Do not use any tool in this work.
• Do not bend or twist the nylon tube.
• To protect the tube, cover it with a vinyl bag
after checking.
• When connector and the pipe are stuck, turn
the fuel tank breather tube carefully to free
and then disconnect the tube.
14. REMOVE FUEL TANK TO FILLER PIPE HOSE
Nylon Tube Retainer
(a) Remove the fuel tank inlet hose from the fuel tank.
FU

O-ring Pipe

A139370E01

0 to 3 mm (0 to 0.12 in.) INSTALLATION

1. INSTALL FUEL TANK TO FILLER PIPE HOSE
(a) Hose and pipe connection is as shown in the
illustration.
NOTICE:
The filler hose must be replaced with a new one.
MARKING

LOCATION
A067094E03

2. INSTALL FUEL TANK BREATHER TUBE SUB-

ASSEMBLY
(a) Push in the tube connector to the pipe until the
connector makes a "click" sound and install the
retainer.
NOTICE:
• Check if there is any damage or foreign
objects on the connected part of the pipe.
• After connecting, check if the pipe and the
connector are securely connected by pulling
them.

A067097
 1GR-FE FUEL – FUEL TANK FU–33

3. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE

ASSEMBLY
(a) Install a new gasket onto the fuel tank.
(b) Set the fuel suction tube assembly to the fuel tank.
NOTICE:
Be careful not to bend the arm of the fuel sender
gage.
(c) Fit a spline of the fuel suction tube assembly into a
keyway of the fuel tank.
A133779

(d) Install a retainer.

(1) Using a new retainer, align mark on the retainer
Mark with a screw-threads starting point of the fuel
tank.
(2) While holding the fuel suction tube assembly,
tighten the retainer one complete turn by hand.
Screw threads
Starting Point

A151298E01
FU
(e) Using a SST, tighten the retainer one more
complete turn, and position the mark on the retainer
SST into a range A of the fuel tank.
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
HINT:
• Turn the retainer two complete turns and position
the mark within the range A for the installation of
the retainer.
Rib • A rib on the retainer can be fitted into a tip of the
SST.

Mark
A151299E01
 FU–34 1GR-FE FUEL – FUEL TANK

4. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK

RETURN TUBE
(a) Connect the fuel tank main tube with the tube joint
clip.
NOTICE:
• Check that there is no scratch or foreign
objects on the connecting parts.
• Check that the connector is fully inserted.
• Check that the tube joint clip is on the collar
of the connector.
• After installing the tube joint clip, check if the
tubes are securely connected by puling then.

A133782

5. INSTALL FUEL TANK CUSHION

(a) Install 3 new fuel tank cushions to the fuel tank.
6. INSTALL FUEL TANK ASSEMBLY
FU (a) Set a mission jack to the fuel tank.
(b) Install the fuel tank and 2 fuel tank bands with the 2
bolts.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)

A133783

7. CONNECT FUEL TANK BREATHER TUBE SUB-

ASSEMBLY
(a) Push in the tube connector to the pipe until the
connector makes a "click" sound.
NOTICE:
• Check that there is no damage or foreign
objects on the connected part of the pipe.
• After connecting, check if the pipe and the
connector are securely connected by pulling
A067103 them.

8. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK

RETURN TUBE
(a) Push in the tube connector to the pipe until the
connector makes a "click" sound.
NOTICE:
• Check that there is no damage or foreign
objects on the connected part of the pipe.
• After connecting, check if the pipe and the
connector are securely connected by pulling
A067104 them.
 1GR-FE FUEL – FUEL TANK FU–35

9. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-

ASSEMBLY
(a) Set a mission jack to the fuel tank protector.
(b) Install the fuel tank protector with the 6 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
10. CONNECT FUEL TANK TO FILLER PIPE HOSE
0 to 3 mm (0 to 0.12 in.)
(a) Hose and pipe connection is as shown in the
illustration.
11. CHECK FOR FUEL LEAKAGE
12. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the connector.
LOCATION
(b) Install the 3 screws and rear floor service hole
MARKING cover.
A067096E03 (c) Install the rear floor carpet assy.

FU