Toyota 23270-31140
Damper Assembly, Fuel Pressure Pulsation

The service and repair process of the fuel pressure regulator needs technicians to discharge fuel system pressure while removing the negative battery cable. Start service on the fuel pressure regulator by removing the V-bank cover and air cleaner assembly then taking off the No. 2 fuel pipe sub-assembly before removing the fuel pressure regulator assembly by unfastening the 2 bolts from the vacuum hose. Installation of the fuel pressure regulator assembly starts with vacuum hose attachment followed by O-ring application of spindle oil or gasoline to the new O-ring before installation on the fuel pressure regulator. Fasten the two fuel pressure regulator bolts at 9.0 N.m (92 kgf.cm, 80 in.lbf). Connect the No. 2 fuel pipe sub-assembly while installing the air cleaner assembly and reconnect the cable to the negative battery terminal securing it at 3.9 N.m (40 kgf.cm, 35 in.lbf). After taking these steps you need to check for fuel leakage before installing the V-bank cover.

The first step for fuel pressure regulator servicing of the 2AZ-FE engine includes removing the fuel tank assembly while inspecting the tube joint clip for foreign substances and cleaning the O-ring. The tube needs to stay inside a plastic bag rather than being bent because this could harm or contaminate the fuel system. You need to pinch the fuel suction plate and tube before carefully turning it to separate the connection because a damaged clip needs replacement. First detach the fuel tank vent tube set plate by removing its 8 bolts before disconnecting the fuel hose and removing the fuel pump from the fuel tank preserving its structure then discard the gasket from the fuel pump. The technician needs to detach the wire harness and remove the fuel sub-tank assembly by manipulating the E-ring with needle-nose pliers until the sub-tank position is low enough for better access, followed by removing the 2 springs on each shaft before extracting the 2 claws to pull out the sub-tank. To detach the 2 claw-brackets from the bracket use a screwdriver taped at the tip. Detach the 5 filter claws from the assembly without cutting the fuel main tube and disconnect the fuel pump connector before extracting the O-ring from the fuel filter. The last procedure includes removing the fuel pressure regulator assembly from the fuel filter followed by extraction of the 2 O-rings.

Starting the installation of the 2TR-FE engine fuel pressure regulator assembly requires applying a thin layer of gasoline or spindle oil to the O-ring. Secure the 3 bolted fuel pressure regulator with a torque value of 8.5 Nm (87 kgf-cm, 75 in-lbf). You should install the harness clamp bracket followed by tightening its bolt to 8.2 Nm (84 kgf-cm, 73 in-lbf). The engine wire harness clamp should be joined with the VSV connector and throttle with motor body connectors. To complete the procedure connect the No. 2 fuel hose followed by intake air connector installation while applying torque of 3.9 Nm (40 kgf-cm, 35 in-lbf) to the negative battery terminal. Finally, check for fuel leakage.

You should start by mounting the vacuum hose prior to fuel pressure regulator assembly installation. Prepare a new standard O-ring by smearing it with spindle oil or gasoline before installing it onto the fuel pressure regulator assembly. Install the fuel pressure regulator using its 2 bolts which need torquing to 9.0 Nm (92 kgf-cm, 80 in-lbf). The No. 2 fuel pipe sub-assembly installation should follow intake air surge tank routing before attaching the air cleaner assembly with its element. The procedure includes installing the No. 2 air cleaner hose followed by negative battery cable connection. Some systems might require an initialization step after reconnection. The engine requires coolant addition followed by a fuel leak inspection. After installing the V-bank cover proceed to fix the front cowl top panel sub-assembly. The service ends with the installation of the front wiper motor and link assembly then the final step is to install the No. 1 engine under cover.

Pull out the fuel pressure regulator from the fuel tank fuel filter and remove its O-ring.

Connect the cable to the negative battery terminal, check for fuel leaks, install the rear floor service hole cover with the fuel pump connector, and reinstall the rear seat cushion assembly according to its type.

Check that the O-ring is not cracked or jammed.

Install the V-bank cover sub-assembly and perform initialization, as some systems require this after disconnecting the battery terminal.

Reinstall the V-bank cover.

First, install the vacuum hose.

Install the No. 1 engine cover sub-assembly.

First, install the vacuum hose.

Connect the pump harness connector, apply gasoline to a new O-ring, and install it to the fuel filter before attaching the fuel pump.

Remove the fuel tank main tube sub-assembly by detaching the tube joint clip and fuel tank main tube, ensuring to check for foreign matter around the clip and keeping the O-ring clean.

Install the fuel tank as needed.

Discharge the fuel system pressure and disconnect the cable from the negative battery terminal.

Check for fuel leakage.

A light coat of gasoline or spindle oil.

Install it and secure it with the clip.

First, discharge the fuel system pressure.

First discharge the fuel system pressure.

Some systems may need to be initialized after reconnection.

Connect the No. 2 fuel pipe sub-assembly, reinstall the intake air surge tank, air cleaner assembly with element, cool air intake hose, and reconnect the cable to the negative battery terminal.

Remove the three bolts securing the fuel pressure regulator.

8.5 N.m (87 kgf.cm, 75 in.lbf).

Disconnect the cable from the negative battery terminal.