Injector

Aw11 Manual RepairCelica Gts Tachometer Cable

ON-VEHICLE INSPECTION

1. CHECK INJECTOR OPERATION

Check the operating sound from each injector.

(a) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine rpm.

(b) If you have no sound scope, you can check the injector transmission operation with your finger.

If no sound or an unusual sound is heard, check the wiring connector, injector, resistor or injection signal from the computer.

2. MEASURE RESISTANCE OF INJECTOR

(a) Disconnect the injector connector.

(b) Using an ohmmeter, check the resistance of both terminals.

Resistance: 4A-GE Approx. 13.8 ft 4A-GZE Approx. 2.9 ft

REMOVAL OF INJECTOR (4A-GE)

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

2. DISCONNECT FOLLOWING HOSES:

(a) PCV hose from cylinder head cover

(b) Vacuum sensing hose from pressure regulator

3. REMOVE PRESSURE REGULATOR (See page FI-78)

4. REMOVE COLD START INJECTION PIPE (See step 3 on page FI-74)

5. DISCONNECT FUEL PIPE

(a) Remove the inlet pipe mounting bolt.

(b) Remove the union bolt, two gaskets and fuel pipe.

6. DISCONNECT INJECTOR CONNECTORS

7. REMOVE DELIVERY PIPE

(a) Remove the three bolts, and then remove the delivery pipe with the injectors.

NOTE: When removing the delivery pipe, be careful not to drop the injectors.

(b) Remove the four insulators and three collars from the cylinder head.

REMOVE INJECTORS

Pull out the injectors from the delivery pipe.

REMOVAL OF INJECTOR (4A-GZE)

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

2. REMOVE THROTTLE BODY (See page FI-99)

Mk3 Supra Cold Start Injector Switch

3. DISCONNECT COLD START INJECTOR PIPE

(a) Disconnect the cold start injector connector.

(b) Remove the union bolt and two gaskets, and disconnect the fuel pipe.

4. LOOSEN AIR OUT LET DUCT

Loosen the two bolts, two nuts of air outlet duct.

5. REMOVE ACCELERATOR CABLE BRACKET

6. DISCONNECT INJECTOR CONNECTORS

1991 Toyota Corolla Fuel Accelerator

7. DISCONNECT FUEL RETURN PIPE

(a) Remove the clamp bolt, union bolt and two gaskets, and disconnect the fuel pipe.

(b) Disconnect the vacuum hose from pressure regulator.

1996 Toyota Camry Engine Vacum Hoses

8. DISCONNECT EGR VACUUM HOSE FROM MODULATOR

9. REMOVE VACUUM PIPE

Remove the three clamp bolts and vacuum pipe.

10. REMOVE PRESSURE REGULATOR (See page FI-79)

Pulsation Damper Automotive

8. REMOVE FUEL INLET PIPE

(a) Remove the clamp bolt.

(b) Remove the pulsation damper and two gaskets, and disconnect the fuel inlet pipe from the delivery pipe.

9. REMOVE DELIVERY PIPE

(a) Remove the three bolts,and then remove the delivery pipe with the injectors.

NOTE: When removing the delivery pipe, be careful not to drop the injectors.

(b) Remove the four insulators and three collars from the cylinder head.

Injector Insulator

10. REMOVE INJECTORS

Pull out the injectors from the delivery pipe.

CAUTION: When replacing the injector, replace it with one having the same-colored painted mark. Colors: blue, yellow, black, white.

SST (Hose) Pressure Regulator (From Vehicle)

SST (Union)

SST (Clamp)

SST (Union)

SST (Union)

Fuel Filter (On Vehicle)

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SST (Clamp)

Fuel Filter (On Vehicle)

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INSPECTION OF INJECTOR (4A-GE)

1. TEST INJECTION OF INJECTORS

WARNING: Keep clear of sparks during the test.

SST (Hose)

Fuel Filter

SST (Hose)

Fuel Filter

Fuel Hose Disconnect

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(a) Disconnect the fuel hose from the fuel filter outlet.

(b) Connect SST (Union) to the fuel filter outlet. SST 09268-41045 (90405-09015)

NOTE: Use the vehicle's fuel filter.

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(c) Install SST (Union) to the removed pressure regulator.

SST 09268-41045 (09268-41090)

Vinyl Tube

Vinyl Tube

(d) Install SST (Union) to the injector and hold the injector and union with SST (Clamp.)

SST 09268-41045

(e) Put the injector into the graduated cylinder.

NOTE: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out.

(f) Connect the battery cable.

(g) Turn the ignition switch ON. NOTE: Do not start the engine.

(h) Using a service wire, short terminals Fp and +B of the check connector.

NOTE:

• The fuel pump will operate.

• The check connector is located near the resonator.

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(i) Connect SST (Resistor Wire) to the injector and battery for 15 seconds and measure the injection volume with a graduated cylinder.

Test each injector two or three times. If not within specified volume, replace the injector.

SST 09842-30070

Difference between each injector: Less than 5 cc (0.3 cu in.)

2. CHECK LEAKAGE

(a) In the condition above, disconnect SST from the battery and check for fuel leakage from the injector nozzle.

SST 09842-30070

Fuel drop: Less than one fuel drop of fuel per minute

(b) Disconnect the battery cable.

(c) Remove the SST and disconnect the service wire from the terminals Fp and +B.

SST 09268-41045

Pressure Regulator (From Vehicle)

Pressure Regulator (From Vehicle)

Drops Inspection Guru

Fuel Filter

(On Vehicle) R1945

Fuel Filter

(On Vehicle) R1945

INSPECTION OF INJECTOR (4A-GZE)

1. TEST INJECTION OF INJECTORS

WARNING: Keep clear of sparks during the test.

Union Bolt SST

SST (Union)

Fuel _ Filter

Union Bolt SST

SST (Union)

Fuel _ Filter

^ Disconnect New Gasket

Fuel Hose

^ Disconnect New Gasket fit 946

(a) Disconnect the fuel hose from the fuel filter outlet.

(b) Connect SST (Union) to the fuel filter outlet. SST 09268-41045 (90405-09015)

NOTE: Use the vehicle's fuel filter.

Pressure Regulator

Fuel

Reutrn

Hose

Pressure Regulator

Fuel

Reutrn

Hose

SST (Union)

_New Gasket

Union Bolt

SST (Union)

_New Gasket

Union Bolt

(c) Install SST (Union) to the removed pressure regulator.

SST 09268-41045 (09268-41090)

New O-Ring

New O-Ring

SST (Hose) SST (Union) SST (Clamp)

Vinyl Tube fit 948

Vinyl Tube fit 948

(d) Install SST (Union) to the injector and hold the injector and union with SST (Clamp.)

SST 09268-41045

(e) Put the injector into the graduated cylinder.

NOTE: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out.

(f) Connect the battery cable.

(g) Turn the ignition switch ON. NOTE: Do not start the engine.

(h) Using a service wire, short terminals Fp and +B of the check connector.

NOTE:

• The fuel pump will operate.

• The check connector is located near the inter-cooler.

(i) Connect SST (Resistor Wire) to the injector and battery for 15 seconds and measure the injection volume with a graduated cylinder.

Test each injector two or three times. If not within specified volume, replace the injector.

SST 09842-30060

Volume: 80 - 100 cc/15 sec. (4.9 - 6.1 cu in.) Difference between each injector: Less than 5 cc (0.3 cu in.)

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2. CHECK LEAKAGE

(a) In the condition above, disconnect SST from the battery and check for fuel leakage from the injector nozzle.

SST 09842-30060

Fuel drop: Less than one fuel drop of fuel per minute

(b) Disconnect the battery cable.

(c) Remove the SST and disconnect the service wire from the terminals Fp and +B.

SST 09268-41045

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INSTALLATION OF INJECTORS (4A-GE)

1. INSTALL INJECTORS INTO DELIVERY PIPE

(a) Replace the O-ring on to the injector.

(b) Apply a thin coat of gasoline to the O-rings and install the injectors into the delivery pipe.

(c) Make sure that the injectors rotate smoothly.

NOTE: If the injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

INSTALL DELIVERY PIPE WITH INJECTORS

(a) Install the four insulators into the injector hole of the cylinder head.

(b) Install the three collars on the delivery pipe mounting hole of the cylinder head.

(c) Place the injectors together with the delivery pipe on the cylinder head.

(d) Make sure that the injectors rotate smoothly.

(e) Install the three thinner spacers and bolts.

Torque the bolts. Torque: 176 kg-cm (13 ft-lb, 17 Nm)

3. CONNECT INJECTOR CONNECTORS

4. CONNECT FUEL INLET PIPE

(a) Place the fuel inlet pipe with two new gaskets on the delivery pipe.

(b) Install and torque the union bolt. Torque: 300 kg-cm (22 ft-lb, 29 N m)

5. INSTALL COLD START INJECTION PIPE (See steps 3 on page FI-74)

6. INSTALL PRESSURE REGULATOR (See page FI-78)

7. CONNECT FOLLOWING HOSES:

(a) PCV hose to the cylinder head cover.

(b) Vacuum sensing hose to the pressure regulator.

8. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY

9. CHECK FOR FUEL LEAKAGE (See page FI-8)

INSTALLATION OF INJECTORS (4A-GZE)

1. INSTALL INJECTORS INTO DELIVERY PIPE

(a) Replace the O-ring on to the injector.

(b) Apply a thin coat of gasoline to the O-rings and install the injectors into the delivery pipe.

(c) Make sure that the injectors rotate smoothly.

NOTE: If the injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

Toyota Hilux Injector Nozzle Install

2. INSTALL DELIVERY PIPE WITH INJECTORS

(a) Install the four insulators into the injector hole of the cylinder head.

(b) Install the three collars on the delivery pipe mounting hole of the cylinder head.

Aw11 Delivery Pipe

(c) Place the injectors together with the delivery pipe on the cylinder head.

(d) Make sure that the injectors rotate smoothly.

(e) Install the three thinner spacers and bolts.

Torque the bolts. Torque: 175 kg-cm (13 ft-lb, 17 Nm)

3. INSTALL FUEL INLET PIPE

(a) Place the fuel pipe with two new gaskets on the delivery pipe.

(b) Install and torque the union bolt. Torque: 300 kg-cm (22 ft-lb, 29 N-m)

(c) Install the clamp bolt.

4. INSTALL PRESSURE REGULATOR (See page FI-79)

5. INSTALL VACUUM PIPE

Install the vacuum pipe and three clamp bolts.

6. CONNECT EGR VACUUM HOSE TO MODULATOR

Toyota 4runner Vacuum Hose Engine

7. CONNECT FUEL RETURN PIPE

(a) Connect the vacuum hose to the pressure regulator.

(b) Place the fuel with two new gaskets on the pressure regulator.

(c) Install and torque the union bolt.

(d) Install the clamp bolt.

Connect The Dots

8. CONNECT INJECTOR CONNECTORS

9. INSTALL ACCELERATOR CABLE BRACKET

10. INSTALL AIR OUTLET DUCT

Tighten the two bolts and two nuts of air outlet duct. Torque: 100 kg-cm (7 ft-lbf 10 N-m)

11. CONNECT COLD START INJECTOR PIPE

(a) Place the fuel pipe and two new gaskets.

(b) Install and torque the union bolt. Torque: 150 kg-cm (11 ft-lb, 15 N-m)

(c) Connect the cold start injector connector.

12. INSTALL THROTTLE BODY (See page FI-104)

13. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY

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Responses

  • iva greco
    How to remove fuel injectors on mr2 mk1?
    8 years ago
  • panu ridanp
    How to replace injectors on toyota corolla 2001?
    7 years ago

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