Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Fuel Injectors

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REMOVAL & INSTALLATION



1FZ-FE Engine

See Figures 1 through 16

  1. Depressurize the fuel system.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Disconnect the cruise control accelerator cable and throttle cable.
  6.  
  7. Detach the No. 2 PCV hose.
  8.  
  9. Remove the air cleaner hose.
  10.  
  11. Remove the EGR vacuum modulator and valve.
  12.  
  13. Unbolt the heater inlet pipe and air intake chamber.
  14.  



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Fig. Fig. 1: Remove the bolt holding the heater inlet pipe and air intake chamber

  1. Disconnect the PCV hose.
  2.  
  3. Remove the vacuum sensing hose.
  4.  
  5. Remove the water bypass and the EVAP hoses.
  6.  
  7. Disconnect the brake booster hose.
  8.  



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Fig. Fig. 2: Disconnect all of the hoses marked by the arrows

  1. Disconnect the throttle position sensor, idle air control valve, emission control valve set assembly and EGR gas temperature sensor wiring.
  2.  



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Fig. Fig. 3: Unclamp these arrowed terminals

  1. Remove the bolts retaining the power steering reservoir tank.
  2.  
  3. Remove the engine oil dipstick.
  4.  
  5. Unbolt the ground strap.
  6.  



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Fig. Fig. 4: Remove all components marked by the arrows

  1. Remove the intake manifold stay.
  2.  



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Fig. Fig. 5: The intake manifold stay is simply a brace secured by two bolts

  1. Disconnect the vacuum hoses to the Thermal Vacuum Valve (TVV).
  2.  
  3. Remove the water bypass hose from the cylinder head.
  4.  
  5. Remove the air intake chamber and discard of the gaskets.
  6.  



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Fig. Fig. 6: The intake manifold is usually retained by 6 bolts and 2 nuts

  1. Remove the 2 union bolts, gaskets and fuel inlet pipe.
  2.  
  3. Remove the delivery pipe and injectors as follows:
    1. Unsecure the 6 injector connectors.
    2.  
    3. Remove the bolts and delivery pipe together with the 6 injectors. Be careful not to drop the injectors when removing the pipe.
    4.  
    5. Remove the insulators and spacers on the intake manifold.
    6.  
    7. Pull the injectors out of the delivery pipe. Remove the O-rings and grommets from each injector.
    8.  

  4.  
  5. Inspect the injectors.
  6.  



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Fig. Fig. 7: Remove the fuel inlet pipe; it runs down to the fuel filter



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Fig. Fig. 8: The injectors are removed with the fuel delivery pipe

To install:
  1. Install new grommets on each injector, then apply a light coat of gasoline to the new O-rings and install them.
  2.  



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Fig. Fig. 9: Install a new grommet and lubricated O-ring on the injector

  1. While turning the injector left and right, install it to the delivery pipe. Install all 6 injectors.
  2.  



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Fig. Fig. 10: Install each injector to the delivery pipe by pushing while twisting the injector

  1. Position the injector connector upwards. Place new insulators and spacers in position on the intake manifold.
  2.  



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Fig. Fig. 11: Place new insulators and spacers in the indicated positions

  1. Temporarily install the bolts holding the delivery pipe to the intake manifold.
  2.  



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Fig. Fig. 12: Temporarily install the bolts holding the delivery pipe to the intake manifold

  1. Check the the injectors rotate smoothly. If they do not, recheck the position of the O-rings, or replace them.
  2.  
  3. Position the injector connector upward, then tighten the bolts holding the delivery pipe to the intake manifold to 15 ft. lbs. (21 Nm).
  4.  
  5. Attach the injector connectors.
  6.  



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Fig. Fig. 13: Rotate the injectors to ensure their smooth movement. An injector that binds has been improperly installed and may leak



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Fig. Fig. 14: Attach the colored connectors to their correct locations



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Fig. Fig. 15: Exploded view of the components for injector removal-1FZ-FE engine



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Fig. Fig. 16: Exploded view of the components for injector removal-1FZ-FE engine (continued)

  1. Install the fuel inlet pipe with new gaskets, tighten the union bolt to 22 ft. lbs. (29 Nm) and the bolt to 14 ft. lbs. (20 Nm).
  2.  
  3. Install the fuel return pipe with the bolts and tighten to 14 ft. lbs. (20 Nm).
  4.  
  5. Attach the fuel hose to the pressure regulator.
  6.  
  7. Install the air intake chamber with new gaskets, tighten to 15 ft. lbs. (21 Nm).
  8.  
  9. Connect the water bypass hose to the cylinder head.
  10.  
  11. Attach the vacuum hose to the thermal vacuum valve (TVV).
  12.  
  13. Install the intake manifold stay, tighten to 26 ft. lbs. (36 Nm).
  14.  
  15. Attach the ground strap.
  16.  
  17. Install the engine oil dipstick.
  18.  
  19. Install the power steering reservoir tank, tighten to 13 ft. lbs. (18 Nm).
  20.  
  21. Attach the EGR gas temperature sensor, emission control valve set, idle air control valve and throttle position sensor connectors.
  22.  
  23. Secure the brake booster, EVAP, water bypass, vacuum sensing and PCV hoses.
  24.  
  25. Install the bolt that holds the heater inlet pipe and air intake chamber, tighten to 14 ft. lbs. (20 Nm).
  26.  
  27. Install the EGR valve and vacuum modulators.
  28.  
  29. Connect the throttle, accelerator and cruise control actuator cables.
  30.  
  31. Attach the air cleaner and PCV hoses.
  32.  
  33. Fill the cooling system with a water/coolant mixture. Start the engine and top off. Look for leaks.
  34.  

5VZ-FE Engine

See Figures 17, 18, 19, 20, 21 and 22

  1. Depressurize the fuel system.
  2.  
  3. Remove the air cleaner hose.
  4.  



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Fig. Fig. 17: Exploded view of the 5VZ-FE injector components

  1. Remove the air intake chamber.
  2.  
  3. Remove the fuel pressure regulator.
  4.  
  5. Disconnect the fuel inlet pipe.
  6.  



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Fig. Fig. 18: Remove the six mounting bolts from the delivery pipes

  1. Unsecure the injector connections.
  2.  
  3. Unbolt and remove the delivery pipes together with the injectors.
  4.  
  5. Remove the spacers from the intake manifold.
  6.  
  7. Pull the injectors out of the delivery pipes, then remove the O-rings and grommets from each injector.
  8.  

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



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Fig. Fig. 19: Install new O-rings and grommets on each injector



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Fig. Fig. 20: While twisting the injector clockwise and counterclockwise, push it into its delivery pipe

  1. While turning the injector clockwise and counterclockwise, push it into the delivery pipe. Install all of the injectors.
  2.  
  3. Position the injector connector outward.
  4.  
  5. Place the spacers into position on the intake manifold. Temporarily install the bolts to hold the delivery pipes to the intake manifold.
  6.  
  7. Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly. If this has occurred, replace the O-rings with new ones.
  8.  
  9. Position the injector outward, then attach the injector connectors.

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    Fig. Fig. 21: Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly

  10.  

  1. Install the fuel pipe with new gaskets and union bolts, tighten to 25 ft. lbs. (34 Nm). Tighten the bolts retaining the delivery pipes to the intake manifold to 10 ft. lbs. (13 Nm).
  2.  
  3. Temporarily install the union with new gaskets, then connect the fuel pipe. Install the clamp bolt, tighten to 71 inch lbs. (8 Nm).
  4.  



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Fig. Fig. 22: Temporarily install the union with new gaskets, then connect the fuel pipe. Install the clamp bolt and tighten to 71 inch lbs. (8 Nm)

  1. Install the fuel pressure regulator.
  2.  
  3. Inspect the air assist lines and connections. Look for any loose connections, sharp bends or damage.
  4.  
  5. Install the intake air cleaner.
  6.  
  7. Attach the air cleaner hose.
  8.  
  9. Start the engine and check for fuel leaks.
  10.  

TESTING



See Figures 23, 24 and 25

Correct testing of the fuel injectors requires specific equipment not usually available outside a dealership or a fuel lab. It is recommended that any checking or testing of the injectors, other than that included below, be left to a properly equipped service facility.

Injector operation can be checked with the injectors installed in the engine. A sound scope is needed here, a stethoscope-like device available from most auto tool and parts jobbers.



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Fig. Fig. 23: A sound scope is usually used to inspect injector operation



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Fig. Fig. 24: If a sound scope is not available, check the operation with your finger

With the engine running or cranking, check each injector for normal operating noise (a buzzing or humming), which changes in proportion to engine rpm. If a sound scope is not available to you, check injector operation by touching each injector with your finger. It should be buzzing. If no sound or an unusual sound is heard, check the wiring connector, or have the injector checked professionally.

With the engine OFF , measure injector resistance by unplugging the wiring connector from the injector, and connecting an ohmmeter across the injector terminals. Check the continuity at both terminals; resistance should be: cold 12-16 ohms. Resistance will vary with injector temperature.



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Fig. Fig. 25: An ohmmeter is used to check injector resistance

 
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