Toyota Celica 1986-1993 Repair Guide

Fuel Injectors

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REMOVAL & INSTALLATION




CAUTION
On vehicles equipped with inflatable restraints or air bag systems, wait at least 30 seconds after disconnecting the battery cable before performing any other work. The backup power will keep the restraint system energized for a period of time after the battery is disconnected. When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2S-E Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the throttle cable from the throttle linkage, if equipped with automatic transaxle and disconnect the accelerator cable from the throttle linkage.
  6.  
  7. Disconnect the air cleaner hose.
  8.  
  9. Disconnect the following hoses:
    1. Two water by-pass hoses from the throttle body.
    2.  
    3. Two PCV valve hoses from the air intake chamber.
    4.  
    5. Air valve hoses.
    6.  
    7. Brake booster vacuum hose from the intake chamber.
    8.  
    9. Fuel filter hose.
    10.  
    11. Main and return fuel hoses.
    12.  
    13. Vacuum sensing hose.
    14.  
    15. PS and A/C idle-up vacuum hoses.
    16.  
    17. Cruise control actuator vacuum hose.
    18.  

  10.  
  11. Disconnect the cold start injector wire, throttle position sensor wire connector, four injector connectors and oxygen sensor connector.
  12.  
  13. Place a shop towel under the cold start injector pipe and remove the two union bolts and four gaskets. Remove the delivery pipe.
  14.  


WARNING
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 with the throttle body. Remove the gasket and purchase a new one.
  4.  
  5. Unbolt and remove the delivery pipe with the injectors attached.
  6.  


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

  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.  


WARNING
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.

  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.  


WARNING
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 torque them to 9 ft. lbs. (13 Nm).
  2.  
  3. Install the air intake chamber with the four bolts, two nuts and new gasket. Torque the nuts and bolts to 17 ft. lbs. (23 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. Torque the union bolts to 13 ft. lbs. (18 Nm).
  8.  
  9. Connect 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. 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. Short the +B and Fp terminals of the engine check connector.
  22.  
  23. Check all fuel connections for leaks. Correct all fuel leaks immediately.
  24.  
  25. Remove the jumper wire.
  26.  



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Fig. Fig. 1 Replacing injector O-ring and grommet2S-E engine



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Fig. Fig. 2 Installing injector to delivery pipe2S-E engine



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Fig. Fig. 3 Installing delivery pipe with injectors2S-E engine

3S-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the connector 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.  


WARNING
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.  


WARNING
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.  
  3. Lightly coat the O-rings with clean fuel.
  4.  
  5. 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.
  6.  
  7. Place the four insulators and two spacers on the cylinder head.
  8.  
  9. Install the injectors together with the delivery pipe onto the cylinder head.
  10.  
  11. Go to each injector and rotate it by hand. The injector should rotate smoothly.
  12.  


WARNING
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 torque them to 9 ft. lbs. (13 Nm).
  4.  
  5. Install the pulsation damper with two new gaskets on both sides of the fuel hose banjo fitting. Tighten the damper to 25 ft. lbs. (34 Nm).
  6.  
  7. Connect the fuel return hose.
  8.  
  9. Connect 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. Torque the two union bolts to 13 ft. lbs. (18 Nm).
  14.  
  15. Connect 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. Check each component for leakage and run the tip of your finger around each connection.
  22.  



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Fig. Fig. 4 Removing fuel pulsation damper3S-FE engine



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Fig. Fig. 5 Installing injector insulators and spacers3S-FE engine

3S-GE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant.
  4.  
  5. Disconnect the throttle cable and the accelerator cable from the throttle linkage, if equipped.
  6.  
  7. Disconnect the ignition coil connector and the high tension cord, then remove the four nuts, two bolts and the suspension upper brace.
  8.  
  9. Disconnect the air cleaner hose.
  10.  
  11. Remove the ignitor.
  12.  
  13. Remove the throttle body (See Throttle Body).
  14.  
  15. Remove the suspension lower cross member.
  16.  
  17. Remove the intake manifold (See ).
  18.  
  19. Remove the three bolts and the delivery pipe with the injectors.
  20.  
  21. Pull the injectors with the delivery pipe.
  22.  

To install:

  1. Before installing, insert four new insulators into the injector holes on the intake manifold.
  2.  
  3. Install the grommet and a new O-ring to the delivery pipe end of each injector.
  4.  
  5. Apply a thin coat of gasoline to the O-ring on each injector and then press them into the delivery pipe.
  6.  
  7. Install the injectors together with the delivery pipe in the intake manifold. Tighten the three mounting bolts to 14 ft. lbs. (19 Nm).
  8.  
  9. Installation of the remaining components is in the reverse order of removal.
  10.  
  11. Connect the battery and start the engine and check for any fuel leaks.
  12.  



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Fig. Fig. 6 Installing delivery pipe with injectors3S-GE engine



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Fig. Fig. 7 Checking for correct installation by being able to rotate injectors3S-GE engine



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Fig. Fig. 8 Installing injector insulators and spacers3S-GE engine

3S-GTE Engine
1988-89 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the throttle body (See Throttle Body).
  4.  
  5. Remove the fuel pressure regulator.
  6.  
  7. Remove the EGR vacuum modulator
  8.  
  9. Disconnect the electrical connections from fuel injectors.
  10.  
  11. Remove the pulsation damper. Disconnect fuel inlet hose from the delivery pipe.
  12.  
  13. Disconnect the fuel return hose from the return pipe.
  14.  
  15. Remove the delivery pipe and fuel injectors and related components (insulators, spacers, O-ring and grommet). Remove injectors from the delivery pipe.
  16.  

To install:

  1. Apply a thin coat of gasoline to the O-ring on each injector and then press them into the delivery pipe.
  2.  
  3. Install the injectors, together with the delivery pipe, in the intake manifold. Tighten the three mounting bolts to 14 ft. lbs. (19 Nm).
  4.  
  5. Install the pulsation damper. Connect fuel inlet hose to the delivery pipe. Torque the fuel inlet hose and damper to 22 ft. lbs. (29 Nm).
  6.  
  7. Connect the electrical connector at each fuel injector. Install the EGR vacuum modulator.
  8.  
  9. Install the fuel pressure regulator and the throttle body.
  10.  
  11. Connect the battery, start the engine and check for any fuel leaks.
  12.  



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Fig. Fig. 9 Installing injector insulators and spacers1989 3S-GTE engine



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Fig. Fig. 1 0Installing fuel pulsation damper1989 3S-GTE engine

1990-93 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the throttle body (See Throttle Body).
  4.  
  5. Remove the air cleaner, charcoal canister, EGR, VSV and vacuum modulator.
  6.  
  7. Remove the EGR valve and pipe, cold start injector pipe and injector, water bypass hoses and air hose.
  8.  
  9. Disconnect the electrical connections from fuel injectors.
  10.  
  11. Disconnect the fuel inlet hose from the fuel filter.
  12.  
  13. Disconnect the fuel return hose from the fuel pressure regulator.
  14.  
  15. Remove the delivery pipe and fuel injector and regulator assembly (insulators, spacers, O-ring and grommet). Remove injectors from the delivery pipe.
  16.  

To install:

  1. Install the fuel inlet hose to the delivery pipe, torquing the bolt to 69 inch lbs. (7.8 Nm) and the union bolt to 22 ft. lbs. (29 Nm).
  2.  
  3. Install the injectors, together with the delivery pipe and fuel pressure regulator. Tighten the 3 mounting bolts to 14 ft. lbs. (19 Nm).
  4.  
  5. Reconnect the fuel inlet hose and tighten to 22 ft. lbs. (29 Nm). Reconnect the brown No. 1 and 3 injectors and the gray No. 2 and 4 injector connectors.
  6.  
  7. Install the EGR valve and pipe, cold start injector pipe and injector, water bypass hoses and air hose.
  8.  
  9. Install the air cleaner, charcoal canister, EGR VSV and vacuum modulator.
  10.  
  11. Install the throttle body (See Throttle Body).
  12.  
  13. Connect the battery, start the engine and check for any fuel leaks.
  14.  



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Fig. Fig. 1 1Installing new injector insulator1991 3S-GTE engine



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Fig. Fig. 1 2Installing new injector spacer1991 3S-GTE engine



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Fig. Fig. 1 3Installing new injector O-rings1991 3S-GTE engine



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Fig. Fig. 1 4Installing new injector insulator1991 3S-GTE engine

4A-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the vacuum sensing hose from the fuel pressure regulator.
  4.  
  5. Disconnect fuel return hose from fuel pressure regulator.
  6.  
  7. Disconnect electrical connections from fuel injectors.
  8.  
  9. Disconnect fuel inlet hose from delivery pipe.
  10.  
  11. Remove the delivery pipe (2 retaining bolts) and fuel injectors and related components (insulators, spacers, O-ring and grommet). Remove injectors from the delivery pipe.
  12.  

To install:

  1. Apply a thin coat of gasoline to the O-ring on each injector and then press them into the delivery pipe.
  2.  
  3. Install the injectors together with the delivery pipe in the intake manifold. Tighten the 2 mounting bolts to 11 ft. lbs. (15 Nm). Torque the inlet hose union bolt to 22 ft. lbs. (29 Nm).
  4.  
  5. Connect electrical connections to the fuel injectors.
  6.  
  7. Connect the fuel return hose to the fuel pressure regulator.
  8.  
  9. Connect the vacuum sensing hose to the fuel pressure regulator.
  10.  
  11. Start the engine and check for any fuel leaks.
  12.  



Click image to see an enlarged view

Fig. Fig. 1 5Removing delivery pipe and injectors4A-FE engine

5S-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the throttle body assembly as outlined.
  4.  
  5. Remove the cold start injector pipe.
  6.  
  7. Remove the fuel pressure regulator.
  8.  
  9. Disconnect necessary engine wiring and remove the left and right accelerator brackets.
  10.  
  11. Disconnect the electrical connections from fuel injectors.
  12.  
  13. Disconnect wire retaining clamps from the No. 2 timing belt cover and intake manifold as necessary to gain access for removal/installation of fuel injectors.
  14.  
  15. Disconnect the fuel return hose from the return pipe.
  16.  
  17. Remove the delivery pipe and fuel injectors and related components (insulators, spacers, O-ring and grommet). Remove injectors from the delivery pipe.
  18.  

To install:

  1. Apply a thin coat of gasoline to the O-ring on each injector and then press them into the delivery pipe.
  2.  
  3. Install the injectors together with the delivery pipe in the intake manifold. Tighten the 2 mounting bolts to 9 ft. lbs. (13 Nm). Tighten the damper to 25 ft. lbs. (34 Nm).
  4.  
  5. Installation of the remaining components is in the reverse order of removal.
  6.  
  7. Connect the battery, start the engine and check for any fuel leaks.
  8.  

TESTING



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

CHECK INJECTOR RESISTANCE

Disconnect the connector from the injector. With an ohmmeter, measure the resistance between the injector terminals. The resistance should be approximately 1.5-3.0 ohms for the 2S-E engine, 13.8 ohms for the 3S-FE, 3S-GE, 4A-FE and 5S-FE engines, or 2-4 ohms for the 3S-GTE engine. 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 (See Fuel Injectors).
  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 SST No. 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 service 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.
  22.  
  23. Connect SST No. 09842-30020, 30040 or 30070 to the injector and the battery for 15 seconds.
  24.  
  25. Measure the volume injected into the cylinder during the 15 second period. The volume should be:

    2.4-3.1 cu. in. (40-50cc) for the 2S-E and 4A-FE engines
     
    2.7-3.4 cu. in. (45-55cc) for the 3S-FE engine
     
    4.0-5.0 cu. in. (66-82cc) for the 3S-GE engine
     
    6.3-6.7 cu. in. (104-110cc) for the 1988-89 3S-GTE engine
     
    5.8-7.3 cu. in. (95-120cc) for the 1990-93 3S-GTE engine
     
    3.0-3.6 cu. in. (49-59cc) for the 5S-FE engine.
     

  26.  



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Fig. Fig. 1 6Checking injector operation with stethoscope2S-E and 3S-GE engines



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Fig. Fig. 1 7Checking injector resistance2S-E and 3S-GE engines



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Fig. Fig. 1 8

  1. If all four injectors were tested, there should be no less than 0.3 cu. in. (5cc) difference between each injector. If the actual volume does not agree with the specified volume, replace the injector.
  2.  



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Fig. Fig. 1 9Checking injector spray volume2S-E and 3S-GE engines



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Fig. Fig. 2 0Checking injector leakageCelica

CHECK 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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