Toyota Camry 1983-1996 Repair Guide

Fuel Injectors

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See Figure 1



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Fig. Fig. 1: Cross-sectional view of the fuel injector


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



2S-ELC Engine

See Figures 2 and 3



Click image to see an enlarged view

Fig. Fig. 2: When installing a fuel injector, be sure it is placed in correctly

  1. Disconnect the negative battery cable.
  2.  
  3. On 1985-86 vehicles, drain the cooling system.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. On 1983-84 vehicles, loosen the bolts and remove the throttle cable bracket from the throttle body. On 1985-86 vehicles, disconnect the throttle cable from the throttle linkage, if equipped with automatic transaxle and disconnect the accelerator cable from the throttle linkage.
  2.  
  3. Disconnect the air cleaner hose.
  4.  
  5. Disconnect the following hoses:

    Two water by-pass hoses from the throttle body.
     
    Two PCV valve hoses from the air intake chamber.
     
    Air valve hoses.
     
    Brake booster vacuum hose from the intake chamber.
     
    Fuel filter hose.
     
    Main and return fuel hoses.
     
    Label and disconnect the emission control hoses (1983-84)
     
    Vacuum sensing hose (1985-86)
     
    PS and A/C idle-up vacuum hoses (1985-86)
     
    Cruise control actuator vacuum hose (1985-86)
     

  6.  
  7. Disengauge the cold start injector wire, throttle position sensor wire harness, four injector connectors and oxygen sensor connector (1985-86).
  8.  
  9. Place a towel or rag under the cold start injector pipe and remove the two union bolts and four gaskets. Remove the delivery pipe.
  10.  

Loosen the union pipe bolts slowly.

  1. Loosen the EGR valve pipe nut.
  2.  
  3. Remove the two nuts and four bolts and remove the air intake chamber and throttle body. Remove the gasket and purchase a new one.
  4.  
  5. Unbolt and remove the delivery pipe with the injectors attached.
  6.  

When removing the delivery pipe, take care not to drop it as damage to the injectors may result. Also, do not remove the injector cover.

  1. Remove the four insulators from the openings in the intake manifold.
  2.  
  3. Gently pull the injectors from the delivery pipe.
  4.  
  5. Remove the O-rings and grommets from the injectors and purchase new ones.
  6.  

To install:
  1. Install a new grommet and new O-ring onto each injector.
  2.  

Make sure that they are installed evenly to ensure a good seat and save yourself from having to take the injectors out and readjust or replace the O-rings.



Click image to see an enlarged view

Fig. Fig. 3: Cutaway view of the fuel injector installed-1983-86 models

  1. Lightly coat the O-rings with clean fuel and install the injectors into the delivery pipe.
  2.  
  3. Install the insulators into the intake manifold openings.
  4.  
  5. Install the injectors and delivery pipe into the intake manifold. Do not cock the injector, install it straight into the opening using a slight left to right twisting motion. Make sure that the injector connector is facing upward.
  6.  
  7. Go to each injector and rotate it by hand. The injector should rotate smoothly. Make sure that the injector connector is facing upward.
  8.  

If the injectors don't rotate smoothly, the O-rings are probably not installed correctly or the injectors are not installed evenly. If this is the case, you will have the pull the delivery pipe off the intake manifold and look at the O-rings to make sure that they are installed correctly. Adjust the O-rings and, if damaged, replace them.

  1. Install the four delivery pipe retaining bolts and tighten them to 8-11 ft. lbs. (10-15 Nm).
  2.  
  3. Install the air intake and throttle body with the four bolts, two nuts and new gasket. Tighten the nuts and bolts to 15-18 ft. lbs. (20-24 Nm).
  4.  
  5. Tighten the EGR valve pipe nut.
  6.  
  7. Using new gaskets, connect the cold start injector pipe to the delivery pipe and cold start injector. Tighten the union bolts to 11-15 ft. lbs. (10-20 Nm).
  8.  
  9. Engauge the wires, wiring connectors and hoses.
  10.  
  11. Connect the air cleaner hose.
  12.  
  13. Install the throttle cable bracket to the throttle body. On 1985-86 vehicles, connect the accelerator (automatic transaxle) and throttle cables.
  14.  
  15. On 1985-86 vehicles, refill the cooling system with a good brand of ethylene glycol coolant to the proper level.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Turn the ignition switch to the ON position. DO NOT start the engine.
  20.  
  21. On 1983-84 vehicles, short both terminals of the fuel pump check connector with a jumper wire. On 1985-86 vehicles, short the +B and Fp terminals of the engine check connector.
  22.  
  23. Check all fuel connections for leaks using the tip of your finger. Correct all fuel leaks immediately.
  24.  
  25. Remove the jumper wire.
  26.  

3S-FE Engine

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the harness from the cold start injector.
  4.  
  5. Place a towel or rag under the cold start injector pipe and remove the two union bolts, four gaskets and delivery pipe.
  6.  

Loosen the union pipe bolts slowly.

  1. Disconnect the vacuum sensing hose from the fuel pressure regulator.
  2.  
  3. Disconnect the fuel return pipe hose.
  4.  
  5. Remove the pulsation damper with the two gaskets. Discard the gaskets and purchase new ones.
  6.  
  7. Unbolt and remove the delivery pipe with the injectors attached.
  8.  

When removing the delivery pipe, take care not to drop it as damage to the injectors may result.

  1. Remove the four insulators and two spacers from the cylinder head.
  2.  
  3. Gently pull the injectors from the delivery pipe.
  4.  
  5. Remove the O-rings and grommets from the injectors and purchase new ones.
  6.  

To install:
  1. Install a new grommet and new O-ring onto each injector. Make sure that they are installed evenly, to ensure a good seat and save yourself from having to take the injectors out and readjust or replace the O-rings.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Cutaway view of the fuel injector installed-1987-96 models

  1. Lightly coat the O-rings with clean fuel.
  2.  
  3. Install the injectors into the delivery pipe. Do not cock the injector, install it straight into the opening using a light left to right twisting motion.
  4.  
  5. Place the four insulators and two spacers on the cylinder head.
  6.  
  7. Install the injectors together with the delivery pipe onto the cylinder head.
  8.  
  9. Go to each injector and rotate it by hand. The injector should rotate smoothly.
  10.  

If the injectors don't rotate smoothly, the O-rings are probably not installed correctly or the injectors are not installed evenly. If this is the case, you will have the pull the delivery pipe off the intake manifold and look at the O-rings to make sure that they are installed correctly. Adjust the O-rings and, if damaged, replace them.

  1. After the delivery pipe and injectors are properly in place, go to each injector and position the connector so that it is facing upward.
  2.  
  3. Install the two delivery pipe retaining bolts and tighten them to 9 ft. lbs. (12 Nm).
  4.  
  5. Install the pulsation damper with two new gaskets on both sides of the fuel hose "banjo'' fitting. Tighten the damper.
  6.  
  7. Connect the fuel return hose.
  8.  
  9. Attach the injector connectors.
  10.  
  11. Connect the vacuum sensing hose.
  12.  
  13. Using new gaskets, connect the cold start injector pipe to the delivery pipe and cold start injector. Tighten the two union bolts to 13 ft. lbs. (17 Nm).
  14.  
  15. Attach the cold start injector wiring connector.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Short the +B and Fp terminals of the engine check connector with a jumper wire.
  20.  
  21. While the connector is shorted, pinch the fuel return hose. When the pinched, this causes the pressure in the high pressure fuel line to rise to 57 psi. ( kPa) At this time any leaks in any part of the system should be apparent. Carefully look at each component for leakage and run the tip of your finger around each connection.
  22.  

5S-FE Engine

See Figures 4, 5, 6 and 7

  1. With the ignition in the LOCK position, disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Disconnect the accelerator cable from the throttle body. If equipped with automatic transmission, disconnect the throttle cable.
  6.  
  7. Disengage the air intake temperature sensor connector.
  8.  
  9. Disconnect the cruise control actuator cable from the clamp on the resonator.
  10.  
  11. Loosen the air cleaner hose clamp bolt. Disconnect the air cleaner hose from the throttle body. Release the air cleaner clips and remove the air cleaner cap with the resonator and air cleaner hose.
  12.  
  13. Disconnect the wiring to the throttle position sensor and the ISC valve.
  14.  
  15. Label and disconnect the hoses for the PCV, EGR vacuum modulator and EVAP VSV.
  16.  
  17. Remove the 4 bolts holding the throttle body. Label and disconnect the hoses from the throttle body.
  18.  
  19. Remove the throttle body with its gasket.
  20.  
  21. Disconnect the PS vacuum hoses.
  22.  
  23. Label and disconnect the hoses from the EVAP Bi-metal Vacuum Switching Valve (BVSV).
  24.  
  25. Remove the EGR valve and the vacuum modulator.
  26.  
  27. Disconnect the vacuum sensor hose at the air intake chamber, the brake booster vacuum hose and the vacuum sensing hose.
  28.  
  29. If equipped with air conditioning, disconnect the magnet switch VSV wiring.
  30.  
  31. Disconnect the ground straps from the intake manifold.
  32.  
  33. Disconnect the knock sensor and EGR Vacuum Switching Valve (VSV) wiring.
  34.  
  35. Free the engine wire harness by removing the bolt and wire clamp.
  36.  
  37. Remove the stays or supports holding the air intake chamber and the intake manifold.
  38.  
  39. Remove the intake manifold and remove the gasket.
  40.  
  41. Disconnect the wiring to each injector.
  42.  
  43. Loosen the pulsation damper and disconnect the fuel inlet pipe. Disconnect the fuel return hose.
  44.  



Click image to see an enlarged view

Fig. Fig. 5: Loosening and removing the pulsation damper-5S-FE engine

  1. Remove the retaining bolts; remove the delivery pipe or fuel rail along with the injectors. Do not drop any injectors during removal.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Unbolt and remove the fuel delivery pipe and injectors as an assembly

  1. Remove the insulators and rail spacers from the head. Remove the injectors from the fuel rail.
  2.  
  3. Remove the O-ring and grommet from each injector.
  4.  

To install:
  1. Install a new grommet on each injector. Apply a light coat of gasoline to new O-rings and install them on each injector.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: Place new injector seals and spacers in position on the cylinder head-5S-FE engine shown

  1. Install the injectors into the fuel rail while turning each left and right. After installation, check that the injectors turn freely in place; if not, remove the injector and inspect the O-ring for damage or deformation.
  2.  
  3. Place new insulators and spacers on the head.
  4.  
  5. Install the fuel rail and injectors; check that the injectors still turn freely in position. Position the injector connectors upward.
  6.  
  7. Install the retaining bolts, tightening them to 9 ft. lbs. (13 Nm).
  8.  
  9. Connect the fuel return hose. Install the fuel inlet pipe and pulsation damper to the delivery pipe. Use new gaskets; tighten the union bolt to 25 ft. lbs. (34 Nm).
  10.  
  11. Connect the wiring to each injector.
  12.  
  13. Using a new gasket, install the intake manifold. Make certain all related wiring is in place before installation. Tighten the retaining nuts and bolts evenly in several passes to 14 ft. lbs. (19 Nm).
  14.  
  15. Install the air chamber and manifold stays. Tighten the 14mm bolt to 31 ft. lbs. (42 Nm) and the 12mm bolt to 16 ft. lbs. (22 Nm).
  16.  
  17. Position and secure the engine wire harness; tighten the clamp and bolt.
  18.  
  19. Connect the wiring to the knock sensor and the EGR VSV.
  20.  
  21. Connect both engine ground straps to the intake manifold.
  22.  
  23. Connect the A/C magnet switch wiring if it was removed.
  24.  
  25. Install the hoses for the vacuum sensor, brake booster and vacuum sensing hose.
  26.  
  27. Install the EGR valve and vacuum modulator. Use new gaskets. Tighten the union nut to 43 ft. lbs. (59 Nm) and the bolt to 9 ft. lbs. (13 Nm).
  28.  
  29. Connect the hoses to the charcoal canister and EGR VSV; connect the wiring to the EGR temperature sensor if it was removed.
  30.  
  31. Connect the vacuum hoses to the EVAP BVSV. Install the 2 PS vacuum hoses.
  32.  
  33. Connect the air and coolant hoses to the throttle body. Install a new gasket, taking note of the correct gasket placement. Install the throttle body, tightening the bolts evenly and alternately to 14 ft. lbs. (19 Nm).
  34.  

The upper mounting bolts are shorter than the lower mounting bolts. Make certain the bolts are correctly placed before tightening.

  1. Connect the PCV, EGR vacuum modulator and EGR VSV hoses to the throttle body. Connect the wiring for the throttle position sensor.
  2.  
  3. Install the air cleaner cap, resonator and intake hose.
  4.  
  5. Connect the wiring to the air intake temperature sensor; reinstall the cruise control actuator cable.
  6.  
  7. Reinstall and adjust the throttle control cable if it was removed. Connect the accelerator cable.
  8.  
  9. Refill the engine coolant.
  10.  
  11. Connect the negative battery terminal.
  12.  

2VZ-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. If equipped with automatic transmission, disconnect the throttle control cable from the throttle body and bracket. On all vehicles, disconnect the accelerator cable and bracket from the throttle body and air plenum or intake chamber.
  6.  
  7. Disengage the air flow meter wiring and disconnect the air hoses. Loosen the clamp bolt and disconnect the cap clips; remove the air cleaner cover and the air flow meter with the air cleaner hose.
  8.  
  9. Label and disconnect the following hoses and electrical harnesses: PCV hoses, vacuum sensing (MAP) hose, fuel pressure vacuum solenoid valve hose, emission system vacuum hoses, ISC connector, throttle position sensor and EGR temperature sensor if so equipped.
  10.  
  11. Remove the right upper engine stay.
  12.  
  13. Disconnect the cold start injector harness and fuel hose.
  14.  
  15. Label and disconnect the brake booster vacuum hose, PS vacuum hose and air hose, cruise control vacuum hose, wire harness clamp and fuel pressure vacuum solenoid valve hose.
  16.  
  17. Remove the wire harness clamp and free the wire harness. Disconnect the EGR tube.
  18.  
  19. Remove the 2 bolts holding the engine hanger. Disconnect and remove the air plenum stay from the air plenum.
  20.  
  21. Remove the air plenum or intake chamber with its gasket.
  22.  
  23. Disconnect the cold start injector harness, the coolant temperature sensor harness and the six injector harnesses.
  24.  
  25. Disconnect the wire harness retaining clamps from the left side fuel rail.
  26.  
  27. Disconnect the fuel return hoses from the fuel pressure regulator and the No. 1 fuel rail. Disconnect the fuel inlet hose from the fuel filter.
  28.  
  29. Remove the No. 2 fuel line.
  30.  
  31. Remove the 2 bolts. Remove the left fuel rail together with the 3 injectors. Take great care not to drop an injector during removal.
  32.  
  33. Remove the 3 bolts, then remove the right fuel rail along with the injectors. Take great care not to drop an injector during removal.
  34.  
  35. Remove the injectors from the fuel rail. Remove the 6 insulators from the intake manifold and remove the spacers from the fuel rail mounting points.
  36.  

To install:
  1. Install a new grommet to each injector.
  2.  
  3. Lightly coat new O-rings with clean gasoline; install the O-rings on each injector.
  4.  
  5. Install the injectors into the fuel rails while turning the injector left and right. Once installed, the injector should turn freely. If any binding is felt, remove the injector and inspect the O-ring for crimping or damage.
  6.  
  7. Place the insulators and spacers in place on the manifold.
  8.  
  9. Install the right and left rail assemblies in position on the intake manifold. Again check that the injectors rotate freely. Turn the injector so the electrical connector faces upward.
  10.  
  11. Install the retaining bolts, tightening them to 9 ft. lbs. (13 Nm).
  12.  
  13. Install the No. 2 fuel pipe. The gaskets at the union bolts must be replaced. Tighten the fittings to 24 ft. lbs. (32 Nm).
  14.  
  15. Install the inlet hose to the fuel filter and connect the return hoses to the pressure regulator and No. 1 fuel line. The washers at the union bolts must be replaced with new ones.
  16.  
  17. Connect the wire harness clips to the left fuel rail.
  18.  
  19. Attach the wiring connectors to the injectors, the cold start injector and the coolant temperature sensor.
  20.  
  21. Install the air intake chamber, tightening the nuts and bolts to 32 ft. lbs. (43 Nm).
  22.  
  23. Connect the EGR tube. Tighten it to 58 ft. lbs. (78 Nm).
  24.  
  25. Connect the wire harness clamp.
  26.  
  27. Install the intake chamber support; install the No. 1 engine hanger. Tighten the mounting bolts for both to 27 ft. lbs. (37 Nm).
  28.  
  29. Install the wire harness clamp, brake booster vacuum hose, PS vacuum and air hoses, cruise control vacuum hose, ground strap connector and fuel pressure vacuum solenoid valve hose.
  30.  
  31. Connect the cold start injector hose.
  32.  
  33. Install the cold start injector wiring.
  34.  
  35. install the upper right engine stay, tightening the bolts to 38 ft. lbs. (52 Nm).
  36.  
  37. Install or connect the wiring or hoses to the ISC, throttle position sensor, EGR temperature sensor, PCV, vacuum components, fuel pressure VSV and coolant by-pass hoses.
  38.  
  39. With the air hose connected, install the air flow meter and air cleaner cover. Secure the 4 clips. Connect the air hoses and attach the wire harness to the air flow meter.
  40.  
  41. Reinstall the accelerator cable and bracket at the throttle body and the air plenum.
  42.  
  43. Install and adjust the throttle control cable if it was removed.
  44.  
  45. Refill the cooling system.
  46.  
  47. Connect the negative battery cable.
  48.  

3VZ-FE Engine

See Figure 8

  1. With the ignition switch in the LOCK position, disconnect the negative battery terminal.
  2.  
  3. Drain the engine coolant.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the air intake chamber and fuel injectors-3VZ-FE engine

  1. Disconnect the accelerator cable from the throttle linkage.
  2.  
  3. If equipped with automatic transmission, disconnect the throttle cable from the linkage.
  4.  
  5. Remove the air cleaner cap, air flow meter and the air cleaner hose as a unit.
  6.  
  7. Remove the two 5mm bolts holding the V-cover; remove the cover.
  8.  
  9. Disconnect the EGR temperature wiring clamp from the set of emission control valves.
  10.  
  11. Label and remove the hoses from the fuel pressure control VSV. Disconnect the hoses, then separate the VSV wiring and remove the emission control valve set.
  12.  
  13. Label and disconnect the brake booster vacuum hose, PS air hose, PCV hose and IACV vacuum hose.
  14.  
  15. Disconnect the two ground straps.
  16.  
  17. Remove the wiring connector from the cold start injector. Disconnect the fuel line from the cold start injector.
  18.  
  19. Remove the No. 1 engine hanger and the air intake chamber support.
  20.  
  21. Remove the EGR pipe.
  22.  
  23. Remove the bolt and disconnect the hydraulic pressure pipe from the air intake chamber.
  24.  
  25. Disconnect the 3 hoses at the air intake plenum, disconnect the two coolant by-pass hoses and the EGR temperature sensor harness if so equipped.
  26.  
  27. Disconnect the throttle position sensor. Detach the connector for the Idle Speed Control (ISC) valve and remove the air hoses from the ISC valve. Remove the PS air hose.
  28.  
  29. Remove the bolts and nuts holding the air plenum, then lift off the unit and gasket.
  30.  
  31. Disconnect the fuel return hoses from the No. 1 fuel pipe; then separate the fuel inlet hose from the filter.
  32.  
  33. Disconnect the wiring from each injector.
  34.  
  35. Remove the No. 2 fuel pipe.
  36.  
  37. Remove the left delivery pipe or fuel rail; be careful not to drop the injectors during removal.
  38.  
  39. Remove the 3 injectors from the delivery pipe. Remove the rail spacers from the intake manifold.
  40.  
  41. Disconnect the two air hoses; remove the air pipe with the hoses attached.
  42.  
  43. Remove the right fuel rail and injectors. Take care not to drop an injector. Remove the injectors from the rail.
  44.  

To install:
  1. Install new grommets on each injector.
  2.  
  3. Apply a light coat of clean gasoline to new O-rings and install 2 on each injector.
  4.  
  5. Install each injector into the fuel rail while turning the injector left and right. Once installed, the injector should turn freely in the rail. If not, remove the injector and inspect the O-ring for damage or dislocation.
  6.  
  7. Place the rail spacers on the manifold. Clean the injector ports and install the right rail and injector assembly. Again check that the injectors turn freely in place.
  8.  
  9. Position the injector wiring connector upward. Install the bolts holding the delivery pipe and tighten them to 9 ft. lbs. (13 Nm).
  10.  
  11. Install the air pipe and hoses; tighten the retaining bolts only to 74 inch lbs. (8.3 Nm).
  12.  
  13. Repeat Steps 28 and 29 to install the left side delivery pipe and injectors.
  14.  
  15. Install the No. 2 fuel pipe connecting the two fuel rails. Use new gaskets at each union bolt. Tighten the union bolts to 25 ft. lbs. (34 Nm).
  16.  
  17. Connect the IACV vacuum hose.
  18.  
  19. Attach the wiring connectors to their proper injectors.
  20.  
  21. Install the inlet hose to the fuel filter using new gaskets; tighten the bolt to 22 ft. lbs. (29 Nm). Connect the return hose to the No. 1 fuel pipe.
  22.  
  23. Using a new gasket, install the air intake chamber. Tighten the mounting nuts to 32 ft. lbs. (43 Nm).
  24.  
  25. Connect the throttle position sensor harness, ISC valve wiring, ISC air hose and PS air hose.
  26.  
  27. Connect the EGR temperature sensor wiring.
  28.  
  29. Install the coolant by-pass hose to the throttle body. Install the coolant by-pass hose to the EGR cooler.
  30.  
  31. Connect the vacuum hoses to the Bi-metal Vacuum Switching Valve (BVSV).
  32.  
  33. Attach the hydraulic pressure pipe to the air intake chamber.
  34.  
  35. Install the EGR pipe with a new gasket and new sleeve ball. Tighten the bolts to 13 ft. lbs. (18 Nm) and the union nut to 58 ft. lbs. (78 Nm).
  36.  
  37. Install the No. 1 engine hanger and the air intake chamber stay. Tighten the bolts to 29 ft. lbs. (39 Nm).
  38.  
  39. Connect the injector pipe with new gaskets to the cold start injector. Tighten the bolts to 11 ft. lbs. (15 Nm). Attach the cold start injector wiring connector.
  40.  
  41. Connect the 2 ground straps.
  42.  
  43. Connect the brake booster vacuum hose, PS air hose, PCV hose and the IACV vacuum hose.
  44.  
  45. Install the emission valve set and tighten the bolts. Connect the VSV wiring and attach the 2 vacuum hoses to the Intake Air Control Valve (IACV) Vacuum Switching Valve (VSV). Install the two hoses to the fuel pressure VSV. Connect the EGR temperature sensor connector clamp to the valve set.
  46.  
  47. Install the V-bank cover on the engine.
  48.  
  49. Install the air cleaner cover, air flow meter and air hose as a unit. Make certain the clips are correctly engaged.
  50.  
  51. Connect and adjust the throttle control cable if it was removed.
  52.  
  53. Connect the accelerator cable and adjust it as needed.
  54.  
  55. Refill the engine coolant.
  56.  
  57. Connect the negative battery cable.
  58.  

1MZ-FE Engine

See Figures 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18

  1. Dsicionnect the negative battery cable.
  2.  


CAUTION
Work must be started approximately 90 seconds or longer after the negative battery cable has been disconnected, if equipped with an air bag.

  1. Drain the engine coolant.
  2.  
  3. Disconnect the accelerator and throttle cables.
  4.  



Click image to see an enlarged view

Fig. Fig. 9: Disconnect the throttle and accelerator cables

  1. Remove the air cleaner and hose assembly.
  2.  
  3. Remove the V-bank cover.
  4.  
  5. Remove the emission valve control set, make sure to label all lines prior to removal.
  6.  
  7. Remove the No. 2 EGR pipe and discard the gaskets.
  8.  
  9. Remove the two bolts, and disconnect the hydraulic motor pressure pipe from the water inlet and air inlet chamber.
  10.  
  11. Remove the air intake chamber assembly.
  12.  
  13. Disconnect the injector wiring.
  14.  
  15. disconnect the air assist pipe from the bracket on the No. 1 fuel pipe. Remove the air assist hoses from the intake manifold.
  16.  



Click image to see an enlarged view

Fig. Fig. 10: Place rags under any fuel hoses being disconnected

  1. Disconnect the fuel return hose from the No. 1 fuel pipe. Disconnect the fuel inlet hose for the fuel filter. Make sure you have a container handy to catch any split fuel.
  2.  



Click image to see an enlarged view

Fig. Fig. 11: Pull all of the hoses from the fuel rail



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Fig. Fig. 12: Remove the end pipe attaching both of the injector rails



Click image to see an enlarged view

Fig. Fig. 13: The pipe contains a union bolt and two washers



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Fig. Fig. 14: Lift the rail and remove the spacers



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Fig. Fig. 15: Remove the injector with O-rings from the manifold



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Fig. Fig. 16: Never reuse old O-rings when installing the old injector



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Fig. Fig. 17: Remember to remove the grommets too



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Fig. Fig. 18: The other side of the injector has two O-rings

  1. Remove the delivery pipes and injectors by performing the following:
    1. Loosen the 2 union bolts holding the No. 2 fuel pipe to the delivery pipes.
    2.  
    3. Disconnect the fuel return hose from the fuel pressure regulator.
    4.  
    5. Remove the union bolt for the right hand delivery pipe, 2 gaskets, 2 bolts, left hand delivery pipe together with the 3 injectors and the No. 2 fuel pipe.
    6.  
    7. Remove the union bolt for the delivery pipe and 2 gaskets from the No. 2 fuel pipe.
    8.  
    9. Remove the 3 bolts, right hand delivery pipe together with the 3 injectors and the No. 1 fuel pipe.
    10.  
    11. Remove the 4 spacers from the intake manifold.
    12.  
    13. Pull out the 6 injectors from the delivery pipes. Remove the two O-rings and two grommets from each injector.
    14.  

  2.  

To install:
  1. Install 2 new grommets to each injector. apply a light coat of fuel to the O-rings and install them to each injector.
    1. While turning the injector clockwise and counterclockwise, push it into the delivery pipes. Install the 6 injectors. Position the injector wiring outward.
    2.  
    3. Place the 4 spacers into position on the intake manifold. Place the right hand delivery pipe and the No. 1 fuel pipe together with the 3 injectors in position on the intake manifold.
    4.  
    5. Temporoirly install the bolt holding the right side delivery pipe to the intake manifold.
    6.  
    7. Place the left hand delivery pipe and the No. 2 fuel pipe together with the 3 injectors in position on the intake manifold.
    8.  
    9. Conhnect the fuel return hose to the fuel pressure regulator. Temporarily install the 2 bolts holding the left hand delivery pipe to the intake manifold.
    10.  
    11. Temporarily install the No. 2 fuel pipe to the left side delivery pipe with the union bolt and 2 new gaskets.
    12.  
    13. Check that the injectors rotate smoothly. If they do not, Replace the O-rings.
    14.  
    15. Position the injector connector outward. Tighten the 4 bolts holding the delivery pipes to the intake manifold and tighten to 7 ft. lbs. (10 Nm). Tighten the bolt holding the No. 1 fuel pipe to the intake manifold to 14 ft. lbs. (20 Nm). Tighten the 2 union bolts holding the no. 2 fuel pipe to the delivery pipes to 24 ft. lbs. (32 Nm).
    16.  

  2.  
  3. Connect the fuel inlet and return hoses. make sure you use new gaskets and union bolt, tighten to 22 ft. lbs. (30 Nm). Connect the fuel return hose to the No. 1 fuel pipe. Pass the fuel return hose under the heater hoses.
  4.  
  5. Install the air assist hoses to the intake manifold and the and air assist pipe to the bracket on the No. 1 fuel pipe.
  6.  
  7. Engauge the fuel injector wiring connectors.
  8.  
  9. Install the air intake chamber assembly. Attach all hoses and wiring removed during installation.
  10.  
  11. Connect the hydraulic motor pressure pipe to the intake chamber, tighten the two bolts to 69 inch lbs. (8 Nm).
  12.  
  13. Install the No. 2 EGR pipe with new gaskets, tighten to 9 ft. lbs. (12 Nm).
  14.  
  15. Install the emission control valve set.
  16.  
  17. Attach the V-bank cover.
  18.  
  19. Install the air cleaner hose.
  20.  
  21. Connect the throttle and accelerator cables.
  22.  
  23. Fill the engine with coolant, connect the negative battery cable.
  24.  
  25. Start the engine and top off the coolant level. Check vehicle operation.
  26.  

TESTING



On-Vehicle Inspection
INJECTOR OPERATION
  1. On V6 engines, remove the V-bank cover.
  2.  
  3. Start the engine.
  4.  
  5. Position the probe of the sound scope (or finger tip) under the base of the injector connector and have an assistant alternately increase the engine rpm and return it to idle.
  6.  
  7. Listen or feel for a change in the operating sound of the injector. The change should be proportional to the increase in engine rpm.
  8.  
  9. If no sound is heard or if the injector sound is unusual, check the connector and wiring, injector, resistor or the signal from the ECU.
  10.  

INJECTOR RESISTANCE

Disconnect the wiring from the injector. With an ohmmeter, measure the resistance between the injector terminals. The resistance should be approximately 1.53.0 ohms for the 2S-ELC engine or 13.8 ohms for all other engines. If the resistance is not as specified, replace the injector. Reconnect the injector connector.

Off-Vehicle Inspection
INJECTOR VOLUME TEST

CAUTION
To avoid personal injury, do not smoke or use any type of open flame when testing the injectors!

  1. Remove the injector(s) from the vehicle and set aside.
  2.  
  3. Place a rag under the "banjo'' fitting and, disconnect the fuel hose from the fuel filter outlet. Remove the gaskets and replace them with new ones.
  4.  
  5. Connect a hose and union (SST 09628-41045) to the fuel filter outlet connection with the new gaskets and tighten the union bolt.
  6.  
  7. Remove the fuel pressure regulator.
  8.  
  9. Connect the fuel return hose to the pressure regulator with the service union with a set of new gaskets and tighten the union bolt.
  10.  
  11. Install a new O-ring onto injector.
  12.  
  13. Connect the special tool to the injector with the service union and clamp the union and the tool to the injector with the service clamp.
  14.  
  15. Connect a length of rubber or vinyl hose to the injector tip to prevent fuel splashing and overspray.
  16.  
  17. Place the injector into a graduated cylinder with metric increments and connect the negative battery cable.
  18.  
  19. Turn the ignition switch ON , but DO NOT start the engine.
  20.  
  21. With a jumper wire, short the +B and FP terminals of the check connector on all engines except 1MZ-FE.
  22.  
  23. On the 1MZ-FE engine, connect the positive and negative leads from the battery to the fuel pump connector.
  24.  
  25. Connect wire (SST 09842-30070) to the injector and the battery for 15 seconds.
  26.  
  27. Measure the volume injected into the cylinder during the 15 second period. The volume should be 3.33.9 cu. inch (5464cc) for the 3.0L engine, 3.4-4.2 cu inch (56-69 cm) on 1MZ-FE engines or 2.73.4 cu. inch (4455cc) for all other engines. If all the injectors were tested, there should be no less than 0.3-0.4 cu. in. (5-6cc) difference between each injector.
  28.  
  29. If the actual volume does not agree with the specified volume, replace the injector.
  30.  
  31. Proceed to the "Check Leakage Rate'' test.
  32.  

LEAKAGE RATE
  1. Leaving everything as it was from the injection test, disconnect the service tool test probes from the battery.
  2.  
  3. Check the injector tip for leakage for a period of one minute. An acceptable leakage rate is one drop.
  4.  
  5. If the leakage exceeds this amount, replace the injector.
  6.  
  7. Disconnect the negative battery cable and remove the all the test equipment.
  8.  
  9. Install the injector(s).
  10.  

 
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