Fuel Injection System - Diesel Toyota Camry V10

DESCRIPTION

The injection system used in the Toyota Camry Turbo Diesel and Corolla FWD Diesel includes a fuel injection pump, injection nozzles, fuel filter, fuel lines and glow plug system. The fuel filter includes an integral priming pump, fuel heater and a water/sediment level warning switch.

The glow plug system has a preheating timer (on right kick panel on Corolla; under center glove compartment on Camry). System also features 2 glow plug relays (located on right fender apron), a current sensor, speed sensor, glow indicator light, resistor and water temperature sensor.

FUEL INJECTION PUMP

The injection pump is driven by a belt at the front of the engine. (Scheme 42) It draws fuel from the tank, pressurizes it, and injects a specific quantity to each cylinder at the proper time. Excess fuel is returned to the tank through another line. The injection pump is not serviceable and should not be disassembled.

Note. Air conditioned vehicles have a vacuum unit that increases idle speed when the air conditioning is on.

Toyota Diesel Fuel Injection Pump Components. Scheme 42

INJECTION NOZZLES

The injection nozzles spray fuel into a prechamber as each compression stroke occurs. Each nozzle has a fuel supply and return line. Nozzles can be disassembled, cleaned and adjusted to correct defective spray patterns. (Scheme 43)

Exploded View of Fuel Injection Nozzle. Scheme 43

Shims are used to correct nozzle opening pressures, and are available in 43 sizes in increments of .001" (.025 mm) from .035-.077" (0.9-1.95 mm). Changing one size nozzle shim will change injection pressure by 50 psi (3.5 kg/cm 2 ). Never use more than one shim.

FUEL FILTER

The fuel filter is a sealed cartridge type, located on the firewall. The cartridge should be changed at regular intervals. When replaced, it should be installed by hand, never with a wrench.

WATER-IN-FUEL WARNING SYSTEM

The fuel injection system includes a water and sediment filter in addition to the sealed cartridge filter. (Scheme 44) This unit traps water which may be present in the fuel system and holds it, preventing damage to the injection pump.

Fuel Filter and Water-In-Fuel Warning System. Scheme 44

A warning light or buzzer signals when the water level is high enough to require draining. A float is lifted by the water level, causing a magnetic switch to close and provide continuity to the warning light or buzzer circuit. A small hand pump is provided so the water separator and filter can be purged of air.

GLOW PLUGS

The glow plug system uses a preheating timer and 2 relays to control glow plug current. (Scheme 48) The glow plugs enable the engine to start easily in cold weather and run smoothly during warm-up.

Current is applied to the glow plugs for a specific time which is determined by engine coolant temperature.

Scheme 45

1. Remove distributor head bolt on injection pump. Install special alignment tool (Toyota Part No. 09275-54010) and dial indicator to distributor head plug. (Scheme 45) (Scheme 45): Injection Pump Timing Install special tool and dial indicator as shown.
2. Set No. 1 or No. 4 cylinder to 25-30° BTDC on compression stroke. Using a screwdriver, turn cold starting lever counterclockwise approximately 20°. Insert a metal bar.33-39" (8.5-10 mm) thick between cold starting lever and thermowax plunger.
3. Set dial indicator at zero. Check to see that indicator stays at zero when crankshaft pulley is rocked slightly to left and right. Slowly turn pulley until No. 1 or No. 4 cylinder is at TDC.
4. Injection timing (dial indicator plunger lift) should be.0315" (.80 mm).
5. Loosen injection pipe union nuts and pump mounting bolts and nuts. Tilt pump body slightly, and recheck injection pump stroke. If stroke is less than specifications, tilt pump toward engine; if greater, tilt away from engine.
6. When timing is correct, tighten pump mounting bolts, nuts and unions of fuel lines. Remove metal bar from cold starting lever. Remove tools, and install distributor head bolt and washer. Tighten to 12 ft. lbs. (17 N.m). Start engine and check for leaks.

IDLE & MAXIMUM SPEED

See TUNE-UP article in TUNE-UP section.

Opening Pressure

1. Blow out any dirt around injection nozzles, then remove fuel lines and nozzles. Mark nozzles for correct installation.
2. Install nozzle on pressure tester. Bleed air from union nut. Pump as hard as possible, several times, to clean out nozzle. Pump up pressure slowly and note when nozzle opens.
3. Opening pressure should be 1920-2205 psi (135-155 kg/cm 2 ) for used nozzles; 2062-2205 psi (145-155 kg/cm 2 ) for new nozzles. There should be no dripping after injection.
4. If pressure is not within these specifications, disassemble and clean nozzle. Change shims as necessary to obtain proper opening pressures. NOTE: Shims are available in 43 sizes in increments of .001" (.025 mm) from .035-.077" (0.9-1.95 mm). Changing nozzle shim by one size will change injection pressure by 50 psi (3.5 kg/cm 2 ). Never use more than one shim.
5. Test nozzle again to ensure opening pressure is correct, then check for leakage.

Leakage Test

Pump pressure slowly until about 142-284 psi (10-20 kg/cm 2 ) BELOW nozzle opening pressure. Hold pressure for at least 10 seconds; no dripping should occur. If nozzle drips, disassemble and clean, or replace. Check spray pattern.

Spray Pattern

Increase pumping speed to 15-60 times per minute for used nozzle; 30-60 times per minute for new nozzles. At certain speeds, nozzle should "shudder" when spraying. Check spray pattern at this speed. If pattern is not correct, clean or replace nozzle. (Scheme 46)

Injection Nozzle Spray Patterns Install tester as shown. Scheme 46

Nozzle Cleaning

1. Disassemble nozzle holder. Wash parts in clean diesel fuel. Use a wooden stick to clean needle tip and soft brass brush to remove nozzle body deposits. Do not touch nozzle tip with fingers.
2. Inspect nozzle seat and needle tip for damage or corrosion. Replace nozzle assembly if either is found. Do not touch nozzle mating surfaces with your fingers. Hold nozzle body at about 60° from horizontal, and insert needle.
3. Pull needle up about one-third its length and allow to slide back down. Repeat several times, rotating needle between test. If needle does not slide down smoothly, replace nozzle assembly.

Indicator Light Circuit

1. Be sure battery voltage is at least 12 volts. Turn ignition switch to "OFF" position. Be sure engine cranks normally and that fusible link is okay. Turn ignition switch to "ON" position. At room temperature, indicator light should light for approximately 3.1 seconds on Corolla models; 2.6 seconds on Camry models. If not, check 7.5 amp fuse and indicator bulb. Repair or replace as necessary.
2. If fuse and bulb are okay, check for battery voltage at terminal 4 of preheating timer connector (on wiring harness side). If voltage is not present, repair wiring. If present, replace preheating timer.

Scheme 47

1. With ignition switch in "ON" position, check for battery voltage at terminal 1 of preheating timer. (Scheme 48) On Camry, check battery voltage at terminal 1, just as ignition switch is turned "ON". If voltage is present, proceed to step 2). If no voltage is present, check for 1 volt at terminals 12 and terminal 6. If 1 volt is not present, replace glow plug current sensor. If 1 volt is present, replace preheating timer.
2. Check that voltage at terminal 1 of preheating timer is no longer present after engine starts. If not, start engine and check if there is voltage at terminal 9 of timer. If not, repair main charging system. If okay, replace timer.
3. If voltage is still present at terminal 1 after starting engine, turn ignition switch to "OFF" position and stop engine. Turn ignition switch to "ON" position and check that current flow to terminal 5 of timer is present according to coolant temperature chart. (Scheme 47) (Scheme 47): Preheating Time/Temperature Chart
4. If no voltage is present, replace timer. If voltage is present for wrong time, disconnect temperature sensor at left rear of engine. Preheating duration should be 70 seconds. If connector is directly grounded, there is no continuity. If voltage is present for length of time, as described, replace water temperature sensor. If time is still incorrect, replace timer.
5. If in step 3), voltage was present at terminal 5 for correct period of time, check for voltage at terminal 5 with ignition at "START" position. If no voltage, replace timer. If voltage is present, turn ignition switch "OFF" position.
6. Turn ignition switch "ON". Check for voltage at glow plugs a few seconds later. If no voltage at all is indicated, check for battery voltage at positive side of glow plug current sensor (resistor side). If present, replace sensor. If not, replace No. 1 glow plug relay.
7. In step 6), voltage at glow plugs should drop from 12 to 6 volts after a few seconds of operation. If not, check for battery voltage at positive side of resistor (intake manifold side). If present, replace resistor. If not, replace No. 2 glow plug relay.
8. If all voltage measurements were correct in steps 6) and 7), check glow plug for continuity. If present, glow plug is okay. If no continuity is indicated, replace glow plug.

GLOW PLUG RELAYS

Connect ohmmeter leads to connector terminals E and g (near tab). (Scheme 49)and (Scheme 50). There should be continuity. Connect leads to terminals B and G. There should be no continuity. Apply battery voltage to terminals E and g. Continuity should now exist between terminals B and G. If continuity is not as specified, replace relay.

Camry & Corolla FWD Glow Plug System Wiring Diagram. Scheme 48

Checking No. 1 Glow Plug Relay. Scheme 49

Checking No. 2 Glow Plug Relay. Scheme 50

GLOW PLUG

Connect ohmmeter to plug terminal and ground. If there is no continuity, replace glow plug.

GLOW PLUG CURRENT SENSOR

Connect ohmmeter leads to current sensor terminals. If there is no continuity, replace current sensor.

RESISTOR

Connect ohmmeter leads to resistor terminals. If there is no continuity, replace resistor.

WATER TEMPERATURE SENSOR

Remove connector and connect ohmmeter leads to water temperature sensor terminals. If resistance does not agree with graph, replace sensor. (Scheme 51)

Water Temperature Sensor Resistance Values. Scheme 51

Solenoid Check

1. Turn ignition switch "ON". Repeatedly connect and disconnect wire at fuel cut solenoid. If a clicking noise is heard, solenoid is okay.
2. If no noise is heard, check 15 amp fuse. If blown, repair short and replace fuse. If fuse is good, apply battery voltage to solenoid and check for noise.
3. If no clicking sound, replace solenoid. If sound is heard, check ignition switch and wiring harness from fuse to fuel cut solenoid.

FUEL HEATER

1. Using an ohmmeter, check resistance between terminals. There should be more than.7 ohm at room temperature.
2. Remove vacuum switch from fuel filter and check continuity between terminals. No continuity should exist. With vacuum of 7.8-11.8 in.Hg. (200-300 mmHg.), check that there is continuity between terminals. If switch fails either test, replace switch.
3. To test fuel relay (located in left kick panel), Test for continuity between terminals 1 and 3. Check terminals 2 and 4 for no continuity. If continuity is not as specified, replace relay. (Scheme 52) To inspect relay operation, connect battery voltage between terminals 1 and 3. Check for continuity between 2 and 4. If operation is not as specified, replace relay.

Checking Fuel Heater Relay. Scheme 52

FUEL FILTER WARNING SWITCH

Remove switch. Connect ohmmeter leads between switch terminals. Pull up on float ("ON" position). Continuity should exist. Push down on float ("OFF" position). There should be no continuity. If readings other than this occur, replace warning switch.

No Fuel at Nozzles

Check fuel cut solenoid. Inspect fuel lines to fuel filter and from fuel filter to pump. Drain water and replace filter. Bleed fuel system. Replace injection pump.

Fuel at Nozzles

Check preheating timer. Check for voltage at glow plugs. Check glow plug continuity. Check fuel leakage, improper injection timing, improper cold start advance and fast idle, and faulty nozzle or holder.

ROUGH IDLE

Adjust accelerator cable. Adjust idle speed. Check for fuel or air leaks. Correct injection pump timing. Check injection nozzle opening pressures and adjust or clean nozzles. Check injection pump fuel supply.

ENGINE STOPS SUDDENLY

Check all previous causes for rough idle and an engine that cranks normally but will not start. Check malfunction of fuel cut solenoid and no fuel supply into injection pump.

LACK OF POWER

Check air cleaner is not clogged and engine is not overheating. Adjust accelerator cable and stop screw. Adjust maximum RPM speed. Check that fuel return line fitting on injection pump is marked "OUT" and that it has an inner jet. Check for fuel leaks. Check fuel filter, injection pump timing, and nozzle assemblies.

EXCESSIVE SMOKE

Check that air cleaner is not clogged. Black smoke indicates advanced timing; white smoke indicates retarded injection timing. Clogged fuel filter or nozzles.

EXCESSIVE FUEL CONSUMPTION

Check for slipping clutch, grabbing brakes, wrong size tires, clogged air cleaner and fuel leakage. Check idle and maximum speed adjustments. Adjust injection timing. Check injection nozzle operation.

ENGINE NOISE WHEN WARM

Coolant temperature too low. Check for defective thermostat. Adjust injection timing and nozzle opening pressure.

ENGINE WILL NOT RETURN TO IDLE

Check for binding accelerator linkage. Check adjusting lever on injection pump. Possible defective injection pump.

ENGINE WILL NOT STOP

Disconnect fuel cut solenoid connector. Check for foreign material in fuel cut solenoid or faulty ignition switch.

Scheme 53

1. Disconnect battery ground cable. On Camry models, drain coolant from radiator and engine drain cocks. Remove right front wheel, fender apron seal and washer and radiator reservoir tanks. Remove cruise control actuator.
2. On Corolla models, remove under cover. On all models, remove power steering drive belt, pulley, pump and bracket. Remove A/C idler pulleys and brackets. Remove alternator and bracket.
3. Remove alternator and bracket. If equipped with air conditioning, remove compressor and bracket without disconnecting hoses.
4. Remove 5 bolts and 3 clips securing No. 2 timing belt cover. Set No. 1 cylinder at TDC of compression stroke by aligning camshaft timing pulley mark with top edge of cylinder head. Remove crankshaft pulley. Remove No. 1 timing belt cover and belt guide.
5. On Camry models, jack up engine slightly to remove weight from righthand engine mount. Remove mounting insulator and bracket. On Corolla models, disconnect center engine mounting bolts. Disconnect righthand engine mounting from bracket. Raise engine slightly. Remove mounting bracket. Lower engine and remove timing belt.
6. On all models, if reusing timing belt, scribe a mark on belt, indicating direction of engine rotation. Place match marks on pulleys and timing belt at each position. (Scheme 53) Using screwdriver, remove tension spring from idler pulley, loosen No. 1 idler pulley bolts and remove timing belt. (Scheme 53): Injection Pump Pulley Match Marks Mark belt and pulleys if belt is to be reused.
7. Remove camshaft timing pulley and No. 1 idler pulley. Remove injection pump pulley, using care not to drop pulley as it springs outward. Remove No. 2 idler pulley. Remove oil pump drive pulley, if necessary.
8. Remove crankshaft timing pulley. Disconnect fuel cut solenoid wire and A/C or heater idle up vacuum hose (if present). Remove accelerator connecting rod. Remove No. 1 and No. 2 water by-pass hoses. On Camry models, remove boost compensator hose.
9. Remove injection lines. Remove hoses from fuel inlet and outlet lines, and remove inlet and outlet lines. Check alignment marks on pump and mounting. Remove mounting bolts and nuts, and lift off injection pump.

Scheme 54

1. Align match marks on injection pump and its mounting. Install injection pump and tighten 2 nuts to 13 ft. lbs. (18 N.m). Install 4 bolts in rear bracket. Tighten to 34 ft. lbs. (47 N.m).
2. Install crankshaft timing pulley, oil pump drive pulley (if removed) and No. 2 idler pulley. Aligning key and key groove, install injection pump drive pulley. Do not use impact wrench on pump pulley. Using spanner wrench, tighten pulley nut to 47 ft. lbs. (64 N.m).
3. Temporarily install No. 1 idler pulley finger tight. Be sure bracket can be moved left and right by hand. Align camshaft pin with camshaft timing pulley. Install pulley and tighten nut to 72 ft. lbs. (98 N.m).
4. When installing timing belt, engine should be cold. If installing new belt, align timing and drive pulleys at each position. (Scheme 54) Belt numbers and letters should be readable from rear end of engine. Install timing belt to camshaft pulley. Install belt, in turn, over fuel injection pump, water pump and crankshaft timing pulleys. (Scheme 54): Pulley Alignment for Installing New Drive Belt
5. If reusing original belt, align match marks made earlier on belt and pulleys. (Scheme 53) Also make sure directional arrow marked on belt points in direction of engine rotation.
6. Install timing belt to No. 2 idler pulley and oil pump pulley. Using a screwdriver, install tension spring.
7. Turn crankshaft pulley bolt so engine turns clockwise 2 revolutions, from TDC to TDC. Check that all alignment marks are in correct position. If not, remove belt and repeat procedure.
8. Without moving bracket, tighten No. 1 idler pulley bolts to 27 ft. lbs. (37 N.m). Install righthand engine mounting insulator and lower engine. On Corolla models, install engine mounting center member. On all models, install timing belt guide and No. 1 belt cover. Install washer and set plate, and tighten crankshaft pulley nut to 72 ft. lbs. (98 N.m).
9. Install No. 2 timing belt cover, alternator bracket and alternator and power steering vane pump. Install power steering pulley and drive belt. Install A/C idler pulleys with bracket. Install drive belt.
10. On Camry models, tension new belt to 100-160 lbs. (220-352 kg); used belt to 95-135 lbs. (209-298 kg). On Corolla models, tension new belt to 140-180 lbs. (309-397 kg); used belt to 80-120 lbs. (176-265 kg). Replace under cover. On Camry models, install cruise control actuator.
11. On all models, install fuel outlet and inlet lines. Connect 4 injection lines, fuel hoses, accelerator rod, wiring and vacuum hose (if equipped). Connect battery. On Camry, install right front wheel. On all models, start engine and check for leaks. Check injection timing with dial indicator. Set idle and maximum speed. Road test vehicle.

Removal & Installation

1. Place a container under filter. Disconnect fuel filter warning switch connector. Loosen fuel filter clamp bolt. Drain fuel from filter.
2. Using filter wrench (SST 09228-64010), remove fuel filter assembly. Using pliers, remove warning switch and "O" ring from filter cartridge. Install fuel filter warning switch with new fuel-lubricated "O" ring to new filter cartridge. Apply a thin film of fuel on new filter "O" ring, and install filter by hand.
3. Secure filter with clamp. Connect warning switch connector and install drain plug.
4. Fill fuel filter with fuel, and operate priming pump 30-40 times to force all air out of filter and separator. Start engine and check for fuel leaks.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS