Toyota Cressida and Van 1983-1990

Fuel Injectors

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REMOVAL & INSTALLATION



Cressida
1983-88 Models


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Fig. Fig. 1 Common cutaway view of the fuel injector assembly



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Fig. Fig. 2 Loosen the fuel injector insulators prior to injector rail removal



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Fig. Fig. 3 Be careful not to drop any of the injectors when pulling the injector rail out of the engine



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Fig. Fig. 4 Performing the fuel injector volume test after injector removal-1983-88 Cressida



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Fig. Fig. 5 Setting up for the fuel injector testing after injector removal-1983-88 Cressida



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Fig. Fig. 6 Short terminals Fp and +B of the check connector to test fuel pump operation-1983-88 Cressida



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Fig. Fig. 7 Place a new grommet and O-ring on the injector prior to injector installation



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Fig. Fig. 8 Once the injectors are installed, make sure they rotate freely by hand

  1. Disconnect the negative battery cable. Drain the coolant into a suitable drain pan.
  2.  


CAUTION
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 quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air intake chamber as follows:
  2.  
    1. Disconnect the No.1 water by-pass hose from the ISC valve body.
    2.  
    3. Disconnect the No.2 water by-pass hose from the throttle body.
    4.  
    5. Disconnect the air valve hose from the ISC body.
    6.  
    7. Disconnect the PCV hose from the throttle body.
    8.  
    9. Disconnect the brake booster vacuum hose from the air intake chamber.
    10.  
    11. Disconnect the actuator vacuum hose from the air intake chamber.
    12.  
    13. Label and disconnect the emission control hoses from the throttle body and the air intake chamber that will allow the removal of the vacuum pipe subassembly.
    14.  
    15. Disconnect the accelerator linkage and cable from the throttle body.
    16.  
    17. Unplug the wire connections for the cold start injector, throttle position sensor, ISC valve and vacuum switching valve.
    18.  
    19. Remove the air intake chamber stay bracket.
    20.  
    21. Remove the vacuum pipe subassembly.
    22.  
    23. Loosen the EGR pipe connecting nut.
    24.  
    25. Disconnect the cold start fuel hose from the delivery pipe.
    26.  
    27. Remove the air intake chamber.
    28.  

  3. Remove the distributor assembly as previously outlined in Chapter 3.
  4.  
  5. Remove the No.1 fuel pipe.
  6.  
  7. Disconnect and remove the wiring harness from the injectors.
  8.  
  9. Remove the 4 bolts and then remove the delivery pipe with the injectors.
  10.  
  11. When removing the delivery pipe, be careful not to drop the injectors. Do not remove the injector cover. Remove the 6 insulators from the intake manifold.
  12.  
  13. Inspect the injectors as follows:
  14.  
    1. Disconnect the fuel hose from the fuel filter outlet.
    2.  
    3. Connect a suitable union hose (SST#09268-41045) to the fuel filter. Be sure to use the vehicle's fuel filter.
    4.  
    5. Connect a suitable union hose (SST#09268-41045) to the removed fuel pressure regulator.
    6.  
    7. Connect a suitable union hose (SST#09268-41045) to the injector and hold the injector and union with a suitable holding fixture.
    8.  
    9. Place the injector into a suitable measuring cup. Install a suitable vinyl tubing onto the injector to prevent gasoline from splashing out.
    10.  
    11. Reconnect the negative battery cable. Turn the ignition switch to the ON position but do not start the engine.
    12.  
    13. Using a suitable jumper wire, short terminals Fp and +B of the check connector. This will cause the fuel pump to operate.
    14.  
    15. Connect some suitable wires to the battery and to the injector so as to make the injector spray. Apply battery voltage for approximately 15 seconds and measure the injection volume with the measuring cup.
    16.  
    17. Test the injector at least 2 or 3 times and if the volume is not within specifications, clean or replace the injector.
    18.  
    19. The volume should be 40-50cc in 15 seconds. The difference between each injector should be less than 6cc.
    20.  


To install:

  1. Install the grommet and a new O-ring to the injector.
  2.  
  3. Apply a thin coat of gasoline to the O-rings and install the injectors into the delivery pipe.
  4.  
  5. Install the 6 insulators into the injector holes of the intake manifold.
  6.  
  7. Install the injectors together with the delivery pipe to the manifold. Make sure that the injectors rotate freely.
  8.  

If the injectors do not rotate freely, the probable cause may be incorrect installation of the O-rings. Replace the O-rings.

  1. Install the 4 bolts and tighten to 10 ft. lbs. (14 Nm).
  2.  
  3. Connect and install the wiring harness.
  4.  
  5. Install the No.1 fuel pipe and finger-tighten the pulsation damper and union bolt with new gaskets on the fuel pipe. Tighten them being careful not to bend the pipe.
  6.  
  7. Install the distributor as previously outlined in this guide.
  8.  
  9. Install the air intake chamber as follows:
  10.  
    1. Install the air intake chamber assembly.
    2.  
    3. Reconnect the cold start fuel hose to the delivery pipe.
    4.  
    5. Tighten the EGR pipe connecting nut.
    6.  
    7. Install the vacuum pipe subassembly.
    8.  
    9. Install the air intake chamber stay bracket.
    10.  
    11. Reconnect the wire connections for the cold start injector, throttle position sensor, ISC valve connectors and vacuum switching valve connector.
    12.  
    13. Reconnect the accelerator linkage and cable to the throttle body.
    14.  
    15. Reconnect the emission control hoses to the throttle body and the air intake chamber that allowed the removal of the vacuum pipe subassembly.
    16.  
    17. Reconnect the actuator vacuum hose to the air intake chamber.
    18.  
    19. Reconnect the brake booster vacuum hose to the air intake chamber.
    20.  
    21. Reconnect the PCV hose to the throttle body.
    22.  
    23. Reconnect the air valve hose to the ISC body.
    24.  
    25. Reconnect the No.2 water by-pass hose to the throttle body.
    26.  
    27. Reconnect the No.1 water by-pass hose to the ISC valve body.
    28.  

  11. Check for fuel leakage by turning the ignition switch to the ON position but do not start the engine.
  12.  
  13. Using a suitable jumper wire, short terminals Fp and +B of the check connector. This will cause the fuel pump to operate. Check for fuel leakage and repair as necessary. Remove the jumper wire from the check connector.
  14.  

1989-90 MODELS


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Fig. Fig. 9 During fuel injector removal, unbolt the clamp for the No. 1 fuel pipe



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Fig. Fig. 10 After removing the No. 1 fuel pipe clamp bolts, remove them on the No. 2 fuel pipe



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Fig. Fig. 11 Loosen the locknut retaining the fuel pressure regulator, then remove the regulator



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Fig. Fig. 12 Remove the 3 bolts retaining the delivery pipe which hold the fuel injectors



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Fig. Fig. 13 Performing the fuel injector volume test after injector removal-1989-90 Cressida



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Fig. Fig. 14 Setting up for the fuel injector testing after injector removal-1989-90 Cressida



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Fig. Fig. 15 Short terminals Fp and +B of the check connector to test fuel pump operation-1989-90 Cressida



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Fig. Fig. 16 Install the black rings on the upper portion of each of the three spacers in the delivery pipe mounting hole of the cylinder head



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Fig. Fig. 17 When installing the pressure regulator, turn the unit clockwise until the vacuum pipe faces in this direction

  1. Disconnect the negative battery cable. Drain the coolant into a suitable drain pan.
  2.  


CAUTION
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.

  1. Remove the throttle body assembly as previously outlined in this section.
  2.  
  3. Remove the ISC valve as follows:
  4.  
    1. Unplug the two idle speed valve connectors.
    2.  
    3. Disconnect the two water by pass hoses and the vacuum hoses from the idle speed control valve body.
    4.  
    5. Remove the two idle speed control valve retaining bolts and remove the valve from the vehicle.
    6.  

  5. Disconnect the cold start injector tube from the fuel delivery pipe as follows:
  6.  
    1. Place a suitable shop towel under the cold start injector.
    2.  
    3. Remove the union bolt and 2 gaskets and disconnect the injector tube.
    4.  
    5. Slowly loosen the union bolt, remove the union bolt, 2 gaskets and fuel tube.
    6.  

  7. Unplug the EGR vacuum switching valve connector. Remove the union bolt and the 2 gaskets from the delivery pipe.
  8.  
  9. Remove the union bolt and 2 gaskets from the fuel filter. Remove the clamp bolt and the No.1 fuel pipe with the vacuum switching valve.
  10.  
  11. Disconnect the vacuum sensing hose. Disconnect the fuel hose from the No.2 fuel pipe.
  12.  
  13. Remove the union bolt and 2 gaskets the fuel pressure regulator.
  14.  
  15. Remove the clamp bolts and the No.2 fuel pipe.
  16.  
  17. Loosen the locknut of the fuel pressure regulator and remove the regulator.
  18.  
  19. Remove the 3 bolts and delivery pipe together with the fuel injectors. Be careful not to drop the injectors, when removing the delivery (fuel rail) pipe.
  20.  
  21. Remove the six insulators and three spacers from the cylinder head. Pull the injectors from the delivery pipe.
  22.  
  23. Inspect the injectors as follows:
  24.  
    1. Disconnect the fuel hose from the fuel filter outlet.
    2.  
    3. Connect a suitable union hose (SST#09268-41045) to the fuel filter. Be sure to use the vehicle's fuel filter.
    4.  
    5. Connect a suitable union hose (SST#09268-41045) to the removed fuel pressure regulator.
    6.  
    7. Connect a suitable union hose (SST#09268-01045) to the injector and hold the injector and union with a suitable holding fixture.
    8.  
    9. Place the injector into a suitable measuring cup. Install a suitable vinyl tubing onto the injector to prevent gasoline from splashing out.
    10.  
    11. Reconnect the negative battery cable. Turn the ignition switch to the ON position but do not start the engine.
    12.  
    13. Using a suitable jumper wire, short terminals Fp and +B of the check connector. This will cause the fuel pump to operate.
    14.  
    15. Connect some suitable wires to the battery and to the injector so as to make the injector spray. Apply battery voltage for approximately 15 seconds and measure the injection volume with the measuring cup.
    16.  
    17. Test the injector at least 2 or 3 times and if the volume is not within specifications, clean or replace the injector.
    18.  
    19. The volume should be 69-85cc in 15 seconds. The difference between each injector should be less than 9cc.
    20.  


To install:

  1. Install the grommet and a new O-ring to the injector.
  2.  
  3. Apply a thin coat of gasoline to the O-rings and install the injectors into the delivery pipe. Be sure to turn the injector left and right while installing them into the delivery pipe.
  4.  
  5. Install the 6 insulators into the injector holes of the cylinder head. Install the black rings on the upper portion of each of the 3 spacers. Then install the spacers on the delivery pipe mounting hole of the cylinder head.
  6.  
  7. Install the injectors together with the delivery pipe to the cylinder head. Make sure that the injectors rotate freely.
  8.  

If the injectors do not rotate freely, the probable cause may be incorrect installation of the O-rings. Replace the O-rings.

  1. Position the injector connector upward. Install the 3 bolts and tighten them to 13 ft. lbs. (18 Nm).
  2.  
  3. Install the fuel pressure regulator as follows:
  4.  
    1. Fully loosen the locknut of the pressure regulator.
    2.  
    3. Apply a light coat of gasoline to a new O-ring and install it to the pressure regulator.
    4.  
    5. Thrust the pressure regulator completely into the delivery pipe by hand.
    6.  
    7. Turn the fuel pressure regulator counterclockwise until the vacuum pipe faces in the direction indicated in the figure.
    8.  
    9. Tighten the locknut to 18 ft. lbs (25 Nm).
    10.  

  5. Install the No.2 fuel pipe with the 2 clamp bolts. Connect the pipe with the union and new gaskets. Tighten the union bolt to 18 ft. lbs. (25 Nm). Connect the fuel return line.
  6.  
  7. Connect the No.3 PCV hose. Connect the vacuum sensing hose.
  8.  
  9. Install the No.1 fuel pipe with the vacuum switching valve with the clamp bolt. Connect the pipe to the fuel filter with the union bolt and new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm).
  10.  
  11. Connect the fuel pipe to delivery pipe with the union bolt and new gaskets. Tighten the union bolt to 29 ft. lbs. (39 Nm).
  12.  
  13. Install the cold start injector tube to the fuel delivery pipe.
  14.  
  15. Attach the injector connectors.
  16.  
  17. Install the idle speed control valve assembly.
  18.  
  19. Install the throttle body assembly.
  20.  
  21. Refill the cooling system. Reconnect the negative battery cable.
  22.  
  23. Check for fuel leakage by turning the ignition switch to the ON position but do not start the engine.
  24.  
  25. Using a suitable jumper wire, short terminals Fp and +B of the check connector. This will cause the fuel pump to operate. Check for fuel leakage and repair as necessary. Remove the jumper wire from the check connector.
  26.  

Van


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Fig. Fig. 18 Performing the fuel injector volume test after injector removal-Van



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Fig. Fig. 19 Setting up for the fuel injector testing after injector removal-Van



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Fig. Fig. 20 Short the terminals of the fuel pump check connector to test pump operation-Van



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Fig. Fig. 21 When removing the fuel injectors begin by, disconnecting the throttle cable



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Fig. Fig. 22 Remove the cable bracket from the throttle body



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Fig. Fig. 23 Remove the air cleaner hose



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Fig. Fig. 24 Unplug the vacuum hoses then label them



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Fig. Fig. 25 Unplug the electrical connections from the intake chamber



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Fig. Fig. 26 Remove the intake chamber mounting nuts



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Fig. Fig. 27 Remove the union bolt from the fuel inlet pipe



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Fig. Fig. 28 Loosen the pulsation damper ...



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Fig. Fig. 29 ... and remove the damper and its gaskets



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Fig. Fig. 30 Mark the fuel injectors and connections



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Fig. Fig. 31 Remove the screw retaining the injector harness



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Fig. Fig. 32 Remove the retainers securing the delivery pipe



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Fig. Fig. 33 Remove the delivery pipe along with the fuel injectors



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Fig. Fig. 34 Pull out the insulators, inspect and replace if they are damaged



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Fig. Fig. 35 Before installing the fuel injectors, place the spacers and insulators into the intake manifold-Van

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant system. Disconnect the accelerator cable from the throttle linkage.
  4.  


CAUTION
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.

  1. Disconnect the throttle cable from the throttle linkage on models equipped with an automatic transmission.
  2.  
  3. Remove the air cleaner hose. Label and disconnect the following:

    Cold start injector connector
     
    Air valve connector
     
    PCV hoses
     
    Brake booster vacuum hose
     
    Charcoal canister
     
    Emission control hoses
     

  4.  
  5. Remove the 2 nuts from the air intake chamber. Remove the union nut from the exhaust manifold and EGR valve.
  6.  
  7. Disconnect the cold start injector fuel pipe, the water by-pass hoses and the pressure regulator hose.
  8.  
  9. Remove the air intake chamber brackets. Use a 12mm socket wrench to remove the rear air intake chamber bracket.
  10.  
  11. Remove the air intake chamber with the air valve. Use 10mm and 12mm socket wrenches to remove the air intake chamber with the air vent.
  12.  
  13. Disconnect the fuel inlet pipe and remove the pulsation damper and 2 gaskets.
  14.  
  15. Remove the fuel outlet pipe and remove the union bolt and 2 gaskets.
  16.  
  17. Disconnect the fuel inlet and outlet pipes from the delivery pipe. Remove the bolt, nut and delivery pipe together with the fuel injectors. Be careful not to drop the injectors, when removing the delivery (fuel rail) pipe.
  18.  
  19. Remove the 4 insulators and 2 spacers from the intake manifold. Pull the injectors from the delivery pipe.
  20.  
  21. Inspect the injectors as follows:
  22.  
    1. Disconnect the fuel hose from the fuel filter outlet.
    2.  
    3. Connect a suitable union hose (SST#09268-41045 or equivalent) to the fuel filter. Be sure to use the vehicle's fuel filter.
    4.  
    5. Connect a suitable union hose (SST#09268-41045 or equivalent) to the removed fuel pressure regulator.
    6.  
    7. Connect a suitable union hose (SST#09268-41045 or equivalent) to the injector and hold the injector and union with a suitable holding fixture.
    8.  
    9. Place the injector into a suitable measuring cup. Install a suitable vinyl tubing onto the injector to prevent gasoline from splashing out.
    10.  
    11. Reconnect the negative battery cable. Turn the ignition switch to the ON position but do not start the engine.
    12.  
    13. Using a suitable jumper wire, short terminals of the fuel pump check connector. This will cause the fuel pump to operate.
    14.  
    15. Connect some suitable wires to the battery and to the injector so as to make the injector spray. Apply battery voltage for approximately 15 seconds and measure the injection volume with the measuring cup.
    16.  
    17. Test the injector at least 2 or 3 times and if the volume is not within specifications, clean or replace the injector.
    18.  
    19. The volume should be 45-55cc in 15 seconds. The difference between each injector should be less than 5cc.
    20.  


To install:

  1. Install the grommet and a new O-ring to the injector.
  2.  
  3. Apply a thin coat of gasoline to the O-rings and install the injectors into the delivery pipe. Be sure to turn the injector left and right while installing them into the delivery pipe.
  4.  
  5. Install the 4 insulators ad 2 spacers into the injector holes of the intake manifold.
  6.  
  7. Install the injectors together with the delivery pipe to the intake manifold. Make sure that the injectors rotate freely.
  8.  

If the injectors do not rotate freely, the probable cause may be incorrect installation of the O-rings. Replace the O-rings.

  1. Install the fuel delivery pipe with the bolt and nut.
  2.  
  3. Connect the inlet pipe with the pulsation damper and 2 gaskets. Tighten the pulsation damper to 22 ft. lbs. (29 Nm).
  4.  
  5. Connect the outlet pipe with the union bolt and 2 new gaskets. Tighten the union bolt to 14 ft. lbs. (20 Nm).
  6.  
  7. Install the air intake chamber with the air valve. Use 10mm and 12mm socket wrenches to install the air intake chamber with the air vent.
  8.  
  9. Install the air intake chamber brackets. Use a 12mm socket wrench to install the rear air intake chamber bracket.
  10.  
  11. Reconnect the cold start injector fuel pipe, the water by-pass hoses and the pressure regulator hose.
  12.  
  13. Install the 2 nuts to the air intake chamber. Install the union nut to the exhaust manifold and EGR valve.
  14.  
  15. Install the air cleaner hose. Reconnect the following hoses and connectors:

    Cold start injector connector
     
    Air valve connector
     
    PCV hoses
     
    Brake booster vacuum hose
     
    Charcoal canister
     
    Emission control hoses
     

  16.  
  17. Connect the accelerator cable and adjust it.
  18.  
  19. On models equipped with automatic transmissions, connect the throttle cable and adjust it.
  20.  
  21. Connect the negative battery cable. Refill the coolant system.
  22.  
  23. Check for fuel leakage by turning the ignition switch to the ON position but do not start the engine.
  24.  
  25. Using a suitable jumper wire, short the terminals of the fuel pump check connector. This will cause the fuel pump to operate. Check for fuel leakage and repair as necessary. Remove the jumper wire from the check connector.
  26.  

TESTING





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Fig. Fig. 36 To test the injector on the vehicle, use a sound scope to inspect for any irregular operating noise



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Fig. Fig. 37 If no sound is heard on the scope test, check the continuity with an ohmmeter of the fuel injector-Cressida



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Fig. Fig. 38 Using an ohmmeter to check the injector continuity-Van

  1. With the engine running or cranking, use a sound scope or a large metal rod to check that there is normal operating noise in proportion to the engine rpm.
  2.  
  3. If you do not own a sound scope, you can check the injector transmission with you finger. Be sure that the engine is not hot.
  4.  
  5. If no sound or an unusual sound is heard, check the wiring connector, injector or injection signal from the ECU.
  6.  
  7. Unplug the wiring connector on the fuel injector.
  8.  
  9. Using an ohmmeter, check the continuity of both terminals.
  10.  
  11. The ohmmeter reading should be as follows:

    1983-88 Cressida-1.5-3.0 omega
     
    1989-90 Cressida-14.0 omega
     
    1984-87 Van-1.5-3.0 omega
     
    1988-89 Van-1.1-2.2 omega
     

  12.  
  13. If the resistance is not as specified, replace the injector.
  14.  

 
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