Camry Repair Manual SFI

Camry Repair Manual

DISCON-NECT NEGATIVE (–) TERMINAL CABLE FROM TERY

BAT-HINT:

Any diagnostic trouble code retained by the computer will beerased when the negative (–) terminal cable is removed fromthe battery

Therefore, if necessary, read the diagnosis before removing thenegative (–) terminal cable from the battery

WHEN WORKING ON THE FUEL SYSTEM

(3) When cleaning the engine compartment, be cially careful to protect the electrical system fromwater

espe-(b) Precautions when handling the oxygen sensor

(1) Do not allow oxygen sensor to drop or hit against anobject

(2) Do not allow the sensor to come into contact withwater

SYS-TEM (HAM, CB, ETC.)

If the vehicle is equipped with a mobile communication system,refer to the precaution in the IN section

(a) Separation of the engine oil dipstick, oil filler cap, PCVhose, etc may cause the engine to run out of tune.(b) Disconnection, looseness or cracks in the parts of the airinduction system between the throttle body and cylinderhead will allow air suction and cause the engine to run out

of tune

(a) Before removing SFI wiring connectors, terminals, etc.,first disconnect the power by either turning the ignitionswitch OFF or disconnecting the negative (–) terminalcable from the battery

HINT:

Always check the diagnostic trouble code before disconnectingthe negative (–) terminal cable from the battery

SST

S04600

FuelPumpConnector

Plug

SF–2

–

SFI (5S–FE) SFI SYSTEM

(b) When installing the battery, be especially careful not to correctly connect the positive (+) and negative (–) cables.(c) Do not permit parts to receive a severe impact during re-moval or installation Handle all SFI parts carefully, espe-cially the ECM

in-(d) Be careful during troubleshooting as there are numeroustransistor circuit, and even slight terminal contact cancause further troubles

(e) Do not open the ECM cover

(f) When inspecting during rainy weather, take care to vent entry of water Also, when washing the enginecompartment, prevent water from getting on the SFI partsand wiring connectors

pre-(g) Parts should be replaced as an assembly

(h) Care should be taken when pulling out and inserting ing connectors

wir-(1) Release the lock and pull out the connector, pulling

on the connectors

(2) Fully insert the connector and check that it is locked

(i) Use SST for inspection or test of the injector or its wiringconnector

SST 09842–30070

(a) When disconnecting the high fuel pressure line, a largeamount 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 onits own, turn the ignition switch OFF

(3) Put a container under the connection

(4) Slowly loosen the connection

(5) Disconnect the connection

(6) Plug the connection with a rubber plug

(7) Reconnect the fuel pump connector

(1) Always use 2 new gaskets.

(2) Tighten the union bolt by hand

(3) Tighten the union bolt to the specified torque

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.)

(d) Observe these precautions when removing and installingthe injectors

(1) Never reuse the O–ring

(2) When placing a new O–ring on the injector, takecare not to damage it in any way

(3) Coat a new O–ring with spindle oil or gasoline fore installing–never use engine, gear or brake oil

SFI (5S–FE) SFI SYSTEM

(e) Install the injector to the delivery pipe and cylinder head,

as shown in the illustration

Before installing the injector, must apply spindle oil or oline on the place where a delivery pipe or an intake man-ifold touches an O–ring of the injector

gas-(f) Observe these precautions when disconnecting the fueltube connector (quick type):

(1) Check if there is any dirt like mud on the pipe andaround the connector before disconnecting themand clean the dirt away

(2) Be sure to disconnect with hands

(3) When the connector and the pipe are stuck, pinchthe retainer between the hands, push and pull theconnector to free to disconnect and pull it out Donot use any tool at this time

(4) Inspect if there is any dirt or the likes on the seal face of the disconnected pipe and clean it away

sur-(5) Prevent the disconnected pipe and connector fromdamaging and mixing foreign objects by coveringthem with a vinyl bag

(g) Observe these precautions when connecting the fueltube connector (quick type):

(1) Do not reuse the retainer removed from the pipe.(2) Must use hands without using tools when to removethe retainer from the pipe

(3) Check if there is any damage or foreign objects onthe connected part of the pipe

(5) After having finished the connection, check if thepipe and the connector are securely connected bypulling them.

(6) Check if there is any fuel leakage

(h) Observe these precautions when handling nylon tube.(1) Pay attention not to turn the connected part of thenylon tube and the quick connector with force whenconnecting them

(2) Pay attention not to kink the nylon tube

(3) Do not remove the EPDM protector on the outside

of the nylon tube

(4) Must not close the piping with the nylon tube bybending it

(i) Check that there are no fuel leaks after doing nance anywhere on the fuel system

mainte-(1) Connect a TOYOTA hand–held tester to the DLC3.(2) Turn the ignition switch ON and push the TOYOTAhand–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 ator’s manual for further details

oper-(5) If you have no TOYOTA hand–held tester, connectthe positive (+) and negative (–) leads from the bat-tery to the fuel pump connector

(See page SF–6)(6) Check that there are no leaks from any part of thefuel system

(7) Turn the ignition switch OFF

(8) Disconnect the TOYOTA hand–held tester from theDLC3

(a) Connect a 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’smanual for further details

(e) If you have no TOYOTA hand–held tester, connect thepositive (+) and negative (–) leads from the battery to thefuel pump connector (See step 7)

(f) Check that there is pressure in the fuel inlet hose from thefuel filter

HINT:

If there is fuel pressure, you will hear the sound of fuel flowing

If there is no pressure, check the fusible link, fuses, EFI mainrelay, fuel pump, ECM and wiring connections

(g) Turn the ignition switch OFF

(h) Disconnect the TOYOTA hand–held tester from theDLC3

(a) Check the battery positive voltage is above 12 V

(b) Disconnect the negative (–) terminal cable from the tery

bat-(c) Remove the union bolt and 2 gaskets, and disconnect thefuel inlet hose from the fuel filter outlet

CAUTION:

Put a shop towel under the fuel filter.

Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)

(e) Wipe off any splattered gasoline

(f) Reconnect the negative (–) terminal cable to the battery.(g) Connect a TOYOTA hand–held tester to the DLC3.(See step 1 in check fuel pump operation (a) to (e))(h) Measure the fuel pressure

Fuel pressure:

301 – 347 kPa (3.1 – 3.5 kgf/cm 2 , 44 – 50 psi)

If pressure is high, replace the fuel pressure regulator

If pressure is low, check the fuel hoses, fuel hose connections,fuel pump, fuel filter and fuel pressure regulator

(i) Disconnect the TOYOTA hand–held tester from theDLC3

(j) Start the engine

(k) Measure the fuel pressure at idle

Fuel pressure:

301 – 347 kPa (3.1 – 3.5 kgf/cm 2 , 44 – 50 psi)

(l) Stop the engine

(m) Check that the fuel pressure remains as specified for 5minutes 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, pressureregulator and/or injectors

(n) After checking fuel pressure, disconnect the negative (–)terminal cable from the battery and carefully remove theSST to prevent gasoline from splashing

SST 09268–45014(o) Reconnect the fuel inlet hose with 2 new gaskets and theunion bolt

Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)

(p) Reconnect the negative (–) terminal cable to the battery.(q) Check for fuel leaks (See page SF–1)

CON-NECTOR

Using an ohmmeter, measure the resistance between terminals

4 and 5

Resistance: 0.2 – 3.0 Ω at 20°C (68°F)

If the resistance is not as specified, replace the fuel pump

SFI (5S–FE) FUEL PUMP

Connect the positive (+) lead from the battery to terminal 4 ofthe connector, and the negative (–) lead to terminal 5 Checkthat the fuel pump operates

NOTICE:

to prevent the coil burning out.

possible.

If operation is not as specified, replace the fuel pump or leadwire

CON-NECTOR

Floor Service Hole Cover

Fuel Pump & SenderGauge ConnectorNo.1 Fuel Tank Protector

Fuel Tank Vent Tube Set Plate

No.1 Fuel Tank Protector

Fuel Tank Vent Tube Set Plate

Fuel FilterFuel Pump Flange

Fuel Sender GaugeConnector

GroundPlate

(a) Take out the floor carpet.

(b) Remove the service hole cover

Remove the 2 bolts and No.1 fuel tank protector

Torque: 4 N·m (40 kgf·cm, 35 in.·lbf)

CONNEC-TOR) CAUTION:

the fuel tube connector (quick type) after observing the precautions.

As there is retained pressure in the fuel pipe line, vent it from splashing inside the vehicle compart- ment.

(a) Remove the 6 bolts and fuel tank vent tube set plate

Torque: 4 N·m (40 kgf·cm, 35 in.·lbf)

(b) Pull out the fuel pump assembly

(c) Remove the gasket from the pump assembly

NOTICE:

not bent.

HINT:

At the time of installation, please refer to the following items.Install a new gasket to the pump assembly

REMOVE FUEL PUMP FROM FUEL PUMP BRACKET

(a) Pull off the lower side of the fuel pump from the pumpbracket

(b) Disconnect the fuel hose from the fuel pump, and removethe fuel pump

(c) Remove the rubber cushion from the fuel pump

REMOVE FUEL SENDER GAUGE.

Push down the portion of A with a finger, and push up the

REMOVE FUEL FILTER

(a) Remove the screw, and pull out the fuel filter

(b) Remove the O–ring from the fuel filter

HINT:

At the time of installation, please refer to the following items ply a light coat of gasoline to a new O–ring, and install it to thefuel filter

Ap-Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf)

REMOVE FUEL PUMP FLANGE

Using a screwdriver, remove the snap fit portion in the order of

1, 2 and 3 as shown in the illustration

HINT:

At the time of installation, please refer to the following items ply a light coat of gasoline to a new O–ring of the fuel pump

Using a screwdriver, remove the snap fit portion in the order of

1, 2 and 3 as shown in the illustration

(a) Using a small screwdriver, remove the clip

(b) Pull out the pump filter

HINT:

At the time of installation, please refer to the following items.Install the pump filter with a new clip

SF0DC–01 –

SFI (5S–FE) FUEL PUMP

Type A

Rear Seat Cushion

Floor Service Hole Cover

Fuel Pump & SenderGauge ConnectorNo.1 Fuel Tank Protector

Fuel Tank Vent Tube Set Plate

Fuel PressureRegulatorFuel Filter

Fuel Pump Assembly

SFI (5S–FE) FUEL PRESSURE REGULATOR

FUEL PRESSURE REGULATOR

COMPONENTS

Type B

Rear Seat Cushion

Floor Service Hole Cover

Fuel Pump and SenderGauge ConnectorNo.1 Fuel Tank Protector

Fuel Tank Vent Tube Set Plate

Fuel PressureRegulatorFuel Filter

Fuel Pump Assembly

(a) Remove the screw, and pull out the fuel filter.

(b) Remove the O–ring from the fuel filter

HINT:

At the time of installation, please refer to the following items ply a light coat of gasoline to a new O–ring, and install it to thefuel filter

Ap-Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf)

(a) Remove the screw, and pull out the pressure regulator

Ap-SF0DF–01 –

SFI (5S–FE) FUEL PRESSURE REGULATOR

SoundScope

Check operation sound from each injector

(a) With the engine running or cranking, use a sound scope

to check that there is a normal operating noise in tion to engine speed

propor-(b) If you have no sound scope, you can check the injectortransmission operation with your finger

If no sound or unusual sound is heard, check the wiring tor, injector or injection signal from the ECM

(a) Disconnect the injector connector

(b) Using an ohmmeter, measure the resistance between theterminals

Resistance: 13.4 – 14.2 Ω at 20°C (68°F)

If the resistance is not as specified, replace the injector.(c) Reconnect the injector connector

Delivery Pipe

InjectorConnectorInjector

(a) Disconnect the 4 high–tension cords from the clamps onthe cylinder head cover.

(b) Disconnect the 4 high–tension cords from the sparkplugs

(c) Disconnect the PCV hose from the intake manifold.(d) Disconnect the PCV hose from the cylinder head cover.(e) Disconnect the engine wire clamp from the mounting bolt

of the No.2 timing belt cover

(f) Remove the cylinder head cover (See page EM–33)

NOTICE:

Cover the cylinder head with a clean cloth to prevent dirt, etc getting into the cylinder head.

(a) Disconnect the 4 injector connectors

(b) Remove the 2 bolts holding the delivery pipe to the der head

cylin-(c) Disconnect the delivery pipe from the 4 injectors

(d) Pull out the 4 injectors

NOTICE:

Be careful not to drop the injectors.

(e) Remove the 4 insulators (Except California) and 2spacers from the cylinder head

S05525

SST (Hose)

Union BoltSST (Union)

Injector

Fuel Filter(On Vehicle)

SST(Clamp)

SST(Union)

S05522

S05524

Union BoltGasketSST (Union)

SST (Hose)

P01078

SST(Clamp)O–Ring

Keep injector clean of sparks during the test.

(a) Remove the union bolt and 2 gaskets, and disconnect thefuel inlet hose from the fuel filter outlet

(b) Connect SST (union and hose) to the fuel filter outlet withthe 2 gaskets and union bolts

SST 09268–41047 (90405–09015)

Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)

(c) Install the grommet and O–ring to the injector

(d) Connect SST (union and hose) to the injector, and holdthe injector and union with SST (clamp)

SST 09268–41047 (09268–41100, 09268–41110)(e) Put the injector into the graduated cylinder

NOTICE:

Do not start the engine.

(i) Select the ACTIVE TEST mode on the TOYOTA hand–held tester

(j) Please refer to the TOYOTA hand–held tester operator’smanual for further details

Connect

SST(Wire)

Z09211

California Except California

SF–24

–

SFI (5S–FE) INJECTOR

(k) If you have no TOYOTA hand–held tester, connect thepositive (+) and negative (–) leads from the battery to thefuel pump connector (See page SF–6)

(l) Connect SST (wire) to the injector and battery for 15 conds, and measure the injection volume with a gra-duated cylinder Test each injector 2 or 3 times

SST 09842–30070

Fuel drop: 1 drop or less per 3 minutes

(b) Turn the ignition switch OFF

(c) Disconnect the negative (–) terminal cable from the tery

bat-(d) Remove the SST

SST 09268–41047, 09842–30070(e) Disconnect the TOYOTA hand–held tester from theDLC3

(f) Reconnect the fuel inlet hose to the fuel filter outlet with

2 new gaskets and the union bolt

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

S05976

Upward

TurnConnector

SF–26

–

SFI (5S–FE) INJECTOR

(h) Attach the 4 injectors and delivery pipe assembly to thecylinder head

(i) Temporarily install the 2 bolts holding the delivery pipe tothe cylinder head

(j) Check that the injectors rotate smoothly

HINT:

If injectors do not rotate smoothly, the probable cause is rect installation of O–rings Replace the O–rings

incor-(k) Position the injector connector upward

(l) Tighten the 2 bolts holding the delivery pipe to the cylinderhead

(a) Install the cylinder head cover (See page EM–53)(b) Connect the PCV hose to the intake manifold

(c) Connect the PCV hose to the cylinder head cover.(d) Install the engine wire clamp to the mounting bolt of theNo.2 timing belt cover

(e) Connect the 4 high–tension cords to the spark plugs.(f) Install the 4 high–tension cords to the clamps on the cylin-der head cover

B06469

Heated Oxygen Sensor (Bank 1 Sensor 2)Before installing the heated oxygen sensor,twist the sensor wire counterclockwise

Location of Fuel Tank Cushion

No.1 Fuel Tank

Protector

Fuel Tank Vent

Tube Set Plate

Fuel Pump

Fuel Outlet Tube

Fuel Inlet Pipe

Fuel Inlet Pipe Protector

Heated Oxygen Sensor(Bank 1 Sensor 2)

Heat InsulatorFuel Tank Band

Center Exhaust Pipe

EVAP Line HoseVent Line Hose

30 cm(11.81 in.)

SF–28

–

SFI (5S–FE) FUEL TANK AND LINE

INSPECTION

INSPECT FUEL TANK AND LINE

(a) Check the fuel lines for cracks or leakage, and all tions for deformation

connec-(b) Check the fuel tank vapor vent system hoses and tions for looseness, sharp bends or damage

connec-(c) Check the fuel tank for deformation, cracks, fuel leakage

or tank band looseness

(d) Check the filler neck for damage or fuel leakage

(e) Hose and pipe connections are as shown in the tion

illustra-If a problem is found, repair or replace the parts as necessary

(a) Check that the throttle linkage moves smoothly.

(b) Check the vacuum at each port

Start the engine

Check the vacuum with your finger

Port name At idle Other than idle

Mark R No vacuum No vacuum

(a) Disconnect the sensor connector

(b) Disconnect the vacuum hose from the throttle opener.(c) Apply vacuum to the throttle opener

(d) Using an ohmmeter, measure the resistance betweeneach terminal

Clearance between lever and stop screw

Between terminals Resistance

0 mm (0 in.) VTA – E2 0.2 – 5.7 kΩ Throttle valve fully

open VTA – E2 2.0 – 10.2 kΩ

(e) Reconnect the vacuum hose to the throttle opener.(f) Reconnect the sensor connector

(a) Allow the engine to warm up to normal operating ture

SFI (5S–FE) THROTTLE BODY

(b) Connect a TOYOTA hand–held tester or OBDII scan tool.(1) Remove the fuse cover on the instrument panel.(2) Connect a TOYOTA hand–held tester or OBDIIscan tool to the DLC3

(3) Please refer to the TOYOTA hand–held tester orOBDII scan tool operator’s manual for further de-tails

(c) Check the idle speed

Idle speed: 700 ± 50 rpm

(d) Check and adjust the throttle opener setting speed.(1) Disconnect the vacuum hose from the throttle open-

er, and plug the hose end

(2) Maintain the engine speed at 2,500 rpm

(3) Release the throttle valve

(4) Check that the throttle opener is set

Throttle opener setting speed:

1,300 – 1,500 rpm (w/ Cooling fan OFF)

(5) Using a 2.5 mm hexagon wrench, loosen the locknut and adjust the throttle opener setting speed byturning the throttle opener adjusting screw Tightenthe lock nut

(6) Reconnect the vacuum hose to the throttle opener.(e) Disconnect the TOYOTA hand–held tester or OBDII scantool

B00526

Accelerator Cable

Throttle Cable(A/T)

Throttle Position SensorConnector

IAC Valve Connector

Water Bypass Hose

EVAP Hose

IAT SensorConnector

VSV Connectorfor EVAPAir Cleaner Cap

PCV HoseAir Cleaner Hose

THROTTLE BODY

DISCONNECT THROTTLE CABLE FROM THROTTLE BODY

(a) Disconnect the throttle position sensor connector.(b) Disconnect the IAC valve connector

(c) Disconnect the 2 vacuum hoses from the throttle body

(d) Remove the 3 bolts

(e) Disconnect the throttle body from the intake manifold.(f) Remove the gasket

(g) Disconnect the air hose for air assist system (California)and the 2 water bypass hoses from the throttle body, andremove the throttle body

B00527

B01284

NoClearance

(a) Using a soft brush and carburetor cleaner, clean the castparts

(b) Using compressed air, clean all the passages and tures

aper-NOTICE:

To prevent deterioration, do not clean the throttle position sensor and throttle opener.

(a) Disconnect the throttle opener vacuum hose from thethrottle body

(b) Apply vacuum to the throttle opener

(c) Check that there is no clearance between the throttle stopscrew and throttle lever when the throttle valve is fullyclosed

(d) Reconnect the throttle opener vacuum hose to the throttlebody

(See page SF–29)

(a) Connect the water bypass hose (from the water bypasspipe) to the throttle body.

(b) Connect the water bypass hose (from the water outlet) tothe throttle body

(g) Connect the IAC valve connector

BODY

CONNECT THROTTLE CABLE TO THROTTLE BODY

(a) Initial conditions:

Engine at normal operating temperature

Idle speed set correctly

Transmission in neutral position

(b) Using SST, connect terminals TE1 and E1 of the DLC1.SST 09843–18020

(c) After the engine speed is kept at 900 – 1,300 rpm for 5 conds, check that it returns to idle speed

se-If the engine speed operation is not as specified, check the IACvalve, wiring and ECM

(d) Remove the SST from the DLC1

(a) Disconnect the IAC valve connector

(b) Using an ohmmeter, measure the resistance between minal +B and other terminals (ISCC, ISCO)

Air Hose (California)

Accelerator Cable

Throttle Cable(A/T)

Throttle Position SensorConnector

IAC Valve Connector

Air Cleaner Cap

Air Cleaner Hose

IAC Valve

VSV Connectorfor EVAP

EVAP Hose

IAT SensorConnectorPCV Hose

Remove the 4 screws, IAC valve and gasket.

BatteryOpen

ISCO+B

SF–38

–

SFI (5S–FE) IDLE AIR CONTROL (IAC) VALVE

INSPECTION

INSPECT IAC VALVE OPERATION

(a) Connect the positive (+) lead from the battery to terminal+B and negative (–) lead to terminal ISCC, and check thatthe valve is closed

(b) Connect the positive (+) lead from the battery to terminal+B and negative (–) lead to terminal ISCO, and check thatthe valve is open

If operation is not as specified, replace the IAC valve

(a) Place a new gasket on the throttle body.

(b) Install the IAC valve with the 4 screws

EFI MainRelay

3

51

Battery

SF–40

–

SFI (5S–FE) EFI MAIN RELAY

EFI MAIN RELAY INSPECTION

(a) Inspect the relay continuity

(1) Using an ohmmeter, check that there is continuitybetween terminals 1 and 2

If there is no continuity, replace the relay

(2) Check that there is no continuity between terminals

3 and 5

If there is continuity, replace the relay

(b) Inspect the relay operation

(1) Apply battery positive voltage across terminals 1and 2

(2) Using an ohmmeter, check that there is continuitybetween terminals 3 and 5

If there is no continuity, replace the relay