Toyota 23209-16080 Injector Assy, Fuel

It is possible for an injector to pass various tests but still operate improperly; if malfunctioning is suspected despite passing checks, a dealer should perform a volume test, as it requires specialized tools. To test, use an automotive stethoscope to listen to each injector with the engine running, ensuring a steady clicking sound that varies with engine RPM; if a stethoscope is unavailable, feel for vibrations with your finger. Disconnect the electrical connector from the suspect injector and check the resistance with an ohmmeter, which should be between 1.5 to 3.0 ohms; if not, replace the injector. To remove the injector, relieve fuel pressure, disconnect the negative battery terminal, and disconnect the throttle return spring. Use a screwdriver to pop the throttle link rod loose, remove the PCV hose, and disconnect electrical connectors from the fuel injectors and the cold start injector vacuum switching valve. Remove the VSV hose and disconnect the fuel return line from the pressure regulator, then remove the pulsation damper and disconnect the fuel inlet hose from the fuel rail. Remove the banjo bolt and disconnect the cold start injector pipe from the fuel rail, then take out the three fuel rail mounting bolts, carefully pulling the fuel rail free from the cylinder head while ensuring the injectors do not fall out. Use a side-to-side rocking motion to extract the faulty injector from the fuel rail. For installation, replace the O-ring seal whether installing a new injector or fixing a leaking one, applying a light coat of gasoline to the O-ring before inserting the injector back into the fuel rail, ensuring it rotates smoothly. Lubricate the injector nozzle insulators with a little engine oil for easier insertion into the cylinder head, and follow the reverse order of removal for installation, tightening the fuel rail bolts and pulsation damper to the specified torque.

Disconnect the electrical connector from the cold start injector, noting that the wire clip must be expanded before unlocking the plug from the injector terminal. Ground the connector with a test light and turn the ignition key to Start; the light should illuminate if the circuit is functioning properly. If it does not, inspect the cold start injector electrical circuit for any issues such as an open, short, or bad connection. Remove the two mounting bolts and pull the injector out of the plenum without disconnecting the cold start tube banjo fitting. Reconnect the electrical connector to the injector, place a small container underneath, and turn the ignition key to Start; if the injector is working correctly, it will squirt fuel into the container. If it does not, it needs to be replaced. Disconnect the electrical connector again and check the injector for continuity with an ohmmeter, ensuring the resistance between terminals is between 3 to 5 ohms; if not, replace the injector. Temporarily install the injector mounting bolts, then use a backup wrench to break loose and disconnect the cold start injector tube banjo fitting. Disconnect the electrical connector, remove the two mounting bolts, and take out the injector. Installation follows the reverse order of removal.