fuel injector TOYOTA CAMRY 2000 Service User Guide

Troubleshooting
If the CO/HC concentration does not comply with
regulations, perform troubleshooting in the order
given below.
(a) Check oxygen sensor operation.
(See page EG1±231)
(b) See the table below for possible causes, then inspect
and correct the applicable causes if necessary.
1. Faulty ignitions:
wIncorrect timing
wFouled, shorted or improperly gapped plugs
wOpen or crossed high±tension cords
wCracked distributor cap
2. Incorrect valve clearance
3. Leaky EGR valve
4. Leaky intake and exhaust valves
5. Leaky cylinder
1. Restricted air filter
2. Faulty MFI/SFI systems
wFaulty pressure regulator
wClogged fuel return line
wDefective engine coolant temp. sensor
wDefective intake air temp. sensor
wFaulty ECM
wFaulty injector
wFaulty throttle position sensor
wMAP sensor 1. Vacuum leaks:
wPCV hose
wEGR valve
wIntake manifold
wThrottle body
w!AC valve
wBrake booster line
2. Lean mixture causing misfire
Rough idle
(Black smoke from exhaust) Rough idle
(Fluctuating HC reading) Rough idleProblems
Causes
Normal
High High High
HighLow
± 5S±FE ENGINEENGINE MECHANICALEG1±22

(d) Remove the 2 bolts and delivery pipe together with
the 4 injectors.
NOTICE: Be careful not to drop the injectors when rem±
oving the delivery pips.
(e) Remove the 4 insulators (except California) and 2
spacers from the cylinder head.
(f) Pull out the 4 injectors from the delivery pipe. 26. REMOVE DELIVERY PIPE AND INJECTORS
(a) Disconnect the injector connectors.
(b) Loosen the pulsation damper, and disconnect the fuel
inlet hose.
(c) Disconnect fuel return hose.
(g) California:
Remove the 2 O±rings, insulator and grommet from
each injector.
(h) Except California:
Remove the 0±ring and grommet from each injector. (d) Disconnect the 2 wire clamps from the wire brackets
on the intake manifold.
± 5S±FE ENGINEENGINE MECHANICALEG1±48

(i) Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable
cause is incorrect installation of O±rings. Replace the
O±rings.
(j) Position the injector connector upward. (g) Place the 4 injectors together with the delivery pipe in
position on the cylinder head.
(h) Temporarily install the 2 bolts holding the delivery
pipe to the cylinder head.
(l) Connect the fuel return hose.
(m) Connect the fuel inlet pipe to the delivery pipe with 2 new
gaskets and the pulsation damper.
Torque: 34 N±m (350 kgf±cm, 25 ft±lbf)
(f) Install the following parts to the intake manifold:
(1) 2 spacers
(2) Except California:
4 new insulators
(k) Tighten the 2 bolts holding the delivery pipe to the
cylinder head.
Torque: 13 N±m (130 kgf±cm, 9 ft±lbf)
± 5S±FE ENGINEENGINE MECHANICALEG1±75

ELECTRONIC CONTROL SYSTEM
The CAMRY 5S±FE engine is equipped with a TOYOTA Computer Controlled System (TCCS)
which centrally controls the MFI/SFI, ESA, IAC diagnosis systems etc. by means of an Engine
Control Module (ECM±formerly MFI/SFI computer) employing a microcomputer.
The ECM controls the following functions:
1. Multiport Fuel Injection (MFI)/Sequential Multiport Fuel Injection (SFI)
The ECM receives signals from various sensors indicating changing engine operation conditions
such as:
Intake manifold pressure
Intake air temperature
Engine coolant temperature
Engine speed
Throttle valve opening angle
Exhaust oxygen content etc.
The signals are utilized by the ECM to determine the injection duration necessary for an optimum
air±fuel ratio.
2. Electronic Spark Advance (ESA)
The ECM is programmed with data for optimum ignition timing under all operating conditions.
Using data provided by sensors which monitor various engine functions (RPM, engine coolant
temperature, etc.), the microcomputer (ECM) triggers the spark at precisely the right instant.
3. Idle Air Control (IAC)
The ECM is programmed with target idling speed values to respond to different engine conditions
(engine coolant temperature, air conditioning ON/OFF, etc.). Sensors transmit signals to the ECM
which controls the flow of air through the bypass of the throttle valve and adjusts idle speed to
the target value.
4. Diagnosis
The ECM detects any malfunctions and abnormalities in the sensor network and lights a
malfunction indicator lamp in the combination meter. At the same time, trouble is identified and
a diagnostic trouble code is recorded by the EC
5. The diagnostic trouble code can be read by the
number of blinks of the malfunction indicator lamp when terminals TE1 and E1 are connected.
The diagnostic trouble codes are referred to in later page. (See page EG1±300)
Fail±Safe Function
In the event of the sensor malfunction, a back±up circuit will take over to provide minimal
driveability, and the malfunction indicator lamp will illuminate. The MFI (Multiport Fuel Injection)/SFI (Sequential Multiport Fuel Injection) system is composed
of 3 basic sub±systems: Fuel, Air Induction and Electronic Control Systems.
FUEL SYSTEM
Fuel is supplied under constant pressure to the MFI/SFI injectors by an electric fuel pump. The
injectors inject a metered quantity of fuel into the intake port in accordance with signals from the
ECM (Engine Control Module).
AIR INDUCTION SYSTEM
The air induction system provides sufficient air for engine operation.
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±166

Fuel pumped up by the fuel pump, flows through the fuel filter and is distributed to each injector
at a set pressure maintained by the pressure regulator.
The fuel pressure regulator adjusts the pressure of the fuel from the fuel line (high pressure side)
to a pressure 284 kPa (2.9 kgf/cm
, 41 psi) higher than the pressure inside the cylinder head, and
excess fuel is returned to the fuel tank through the return pipe.
The pulsation damper absorbs the slight fluctuations in fuel pressure caused by fuel injector from
the injector.
The injectors operate on input of injection signals from the ECM and inject fuel into the cylinder
head.
OPERATION
FUEL SYSTEM
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±167

The control system consists of sensors which detect various engine conditions, and a ECM which
determines the injection volume (timing) based on the signals from the sensors.
The various sensors detect the intake air pressure, engine speed, oxygen density in the exhaust
gas, engine coolant temperature, intake air temperature and atmospheric pressure etc. and
convert the information into an electrical signal which. is sent to the ECM. Based on these signals,
the ECM calculates the optimum ignition timing for the current conditions and operates the
injectors.
The ECM not only controls the fuel injection timing, but also the self diagnostic function which
records the occurrence of a malfunction, ignition timing control, idle speed control and EGR
control.
ELECTRONIC CONTROL SYSTEM
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±169

FUEL SYSTEM
1. When disconnecting the high pressure fuel line, a
large amount of gasoline will spill out, so observe the
following procedures:
(a) Put a container under the connection.
(b) Slowly loosen the connection.
(c) Disconnect the connection.
(d) Plug the connection with a rubber plug.
2. When connecting the flare nut or union bolt on the
high pressure pipe union, observe the following proce±
dures:
Union Bolt Type:
(a) Always use a new gasket.
(b) Tighten the union bolt by hand.
(c) Tighten the union bolt to the specified torque.
Torque: 29 N±m (300 kgf±cm, 22 ft±lbf)
Flare Nut Type:
(s) Apply alight coat of engine oil to the flare and tighten
the flare nut by hand.
(b) Using SST, torque the flare nut.
SST 09631±22020
Torque:
28 N±m (285 kgf±cm, 21 ft±lbf) for fuel pump side
30 N±m (310 kgf±cm, 22 ft±lbf) for others
HINT: Use a torque wrench with a fulcrum length of
30 cm (11.81 in.).
3. Observe the following precautions when removing
and installing the injectors.
(a) Never reuse the O±ring.
(b) When placing a new O±ring on the injector, take care
not to damage it in any way.
(c) Coat a new 0± ring with spindle oil or gasoline before
installing±never use engine, gear or brake oil.
4. Install the injector to delivery pipe and intake manifold
as shown in the illustration.
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±175

(q) Stop the engine.
(r) Check that the fuel pressure remains 147 kPa (1.5
kgf/cm
2, 21 psi) or more for 5 minutes after the
engine is turned off.
If pressure is not as specified, check the fuel pump,
pressure regulator and/or injector.
(s) After checking fuel pressure, disconnect the battery
negative (±) cable and carefully remove the SST to
prevent gasoline from splashing.
SST 09268±45012
(t) Connect the fuel inlet hose with 2 new gaskets and
the union bolt.
Torque: 29 N±m (300 kgf±cm. 22 ft±lbf)
(u) Reconnect the cable to the negative (±) terminal of
the battery.
(v) Check for fuel leakage.(o) Reconnect the vacuum sensing hose to the air intake
chamber.
(p) Measure the fuel pressure at idle.
Fuel pressure:
206 ± 255 kPa (2.1 ± 2.6 kgf/cm
, 31 ± 37 psi)
If pressure is not as specified, check the vacuum
sensing hose and fuel pressure regulator.(l) Start the engine.
(m) Disconnect the vacuum sensing hose from the air
intake chamber and plug the air intake chamber
outlet.
(n) Measure the fuel pressure at idle.
Fuel pressure:
265 ± 304 kPa (2.7 ± 3.1 kgf/cm
, 38 ± 44 psi) (k) Remove the SST.
SST 09483±18020
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±180

(c) Remove the 2 bolts and delivery pipe together with
the 4 injectors.
NOTICE: Be careful not to drop the injectors when rem±
oving the delivery pipe.
(d) Remove the 4 insulators (except California) and 2
spacers from the cylinder head.
(e) Pull out the 4 injectors from the delivery pipe. 18. REMOVE DELIVERY PIPE AND INJECTORS
(a) Loosen the pulsation damper, and disconnect the fuel
inlet pipe.
(b) Disconnect the fuel return hose.(c) Disconnect the 2 wire clamps from the wire brackets
on the intake manifold. (b) Remove the 6 bolts, 2 nuts, intake manifold and
gasket.
17. DISCONNECT INJECTOR CONNECTORS
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±194

(c) Install a new O±ring to the fuel inlet of pressure
regulator.
(d) Connect SST (hose) to the fuel inlet of the pressure
regulator with SST (union) and the 2 bolts.
SST 09268±41045 (09268±41090)
Torque: 5.4 N±m (55 kgf±cm, 48 ft±lbf)
(e) Connect the fuel return hose to the fuel outlet of the
pressure regulator with SST (union), 2 new gaskets
and union bolts. (a) Disconnect the fuel hose from the fuel filter outlet.
(b) Connect SST (union and hose) to the fuel filter outlet
with 2 new gaskets and union bolts.
SST 09268±41045 (90405±09015)
Torque: 29 N±m (300 kgf±cm, 22 ft±lbf)
HINT: Use the vehicle's fuel filter.
INJECTORS INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION: Keep injector clear of sparks during the test.
(f) California:
Remove the 2 O±rings, insulator and grommet from
each injector.
(g) Except California:
Remove the O±ring and grommet from each injector.
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±195