Toyota Camry 1983-1996 Repair Guide

Injector

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CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

REMOVAL & INSTALLATION



See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect all the electronic vacuum regulating valve assembly pipe and hoses.
  4.  
  5. Remove the current sensor plate.
  6.  
  7. Disconnect the wire from the injection pump.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the diesel injector

  1. Remove the two nuts and remove the water by-pass support and disconnect the grounding strap.
  2.  
  3. Loosen the clips and remove the injection hoses from between the injection pump and pipe.
  4.  
  5. Disconnect both ends of the injection pipes from the pump and nozzle holders.
  6.  
  7. Remove the nuts, injection pipe clamp and injection pipe assembly.
  8.  
  9. Disconnect the fuel hoses from the leakage pipes.
  10.  
  11. Remove the four nuts, leakage pipe and four washers.
  12.  
  13. Using a socket (SST 09268-64010) or equivalent, unscrew the injection nozzle holders and arrange them in order.
  14.  
  15. Remove the nozzle seats and gaskets. Discard these items and purchase new ones.
  16.  

To install:
  1. Install new nozzle seats and gaskets onto the injectors.
  2.  
  3. Install the injector nozzle holders and tighten them to 47 ft. lbs. (64 Nm).
  4.  


CAUTION
Follow the recommended torque value when tightening the injector nozzle holders. Over tightening the holders could cause nozzle deformation, needle binding, improper sealing and other problems.

  1. Install the nozzle leakage pipe assembly onto the nozzle holder with the washers and four nuts. Tighten the nuts to 22 ft. lbs. (29 Nm).
  2.  
  3. Connect the fuel hose to the leakage pipe.
  4.  
  5. Connect the injector pipes and tighten the connections. Install the injection line clamp.
  6.  
  7. Connect the fuel hoses and make sure the clips are tight.
  8.  
  9. Bleed the system by loosening the pipes at the nozzles and cranking the engine until all air is expelled and fuel sprays.
  10.  
  11. Connect the ground strap and install the water by-pass support.
  12.  
  13. Connect the injection pump wire.
  14.  
  15. Install the current sensor plate.
  16.  
  17. Install the electronic vacuum regulating assembly, pipe and hoses.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the engine and inspect for leaks.
  22.  

TESTING



Injection nozzle testing requires the use of an expensive diesel engine nozzle pressure tester, calibration fluid and also a reasonable familiarity with injection nozzle testing procedures. Normally, the purchase of such equipment is not made by the average DIY'er. Injectors rely on close tolerances for proper fuel injection. Even the smallest speck of dirt caught between the injector nozzle and the nozzle body can lead to the failure of the injector. If you do have a set of injectors that need testing and/or opening pressure adjustment, the matter may be best handled by a qualified technician or an injector specialist.

 
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