Finaly 5AFE Swapped in EE90

[Vaqas1]

Hmm I was having starting problem Xulfiqar bhai also helped and it turned out to be leaking injectors.

2 Weeks ago i changed my Fuel Pump to new one still i was having issue of a engine sitting idle for 20 to 30 mins was taking 4 to 5 turns to start.

Cyl no 4. 3 . 2 Injectors were leaking and i wonder why they all started to leak hmm i guess me running engine without any fuel filter for around 2 month caused this :p.

In this 2nd gen of 5AFE changing injectors is pain in the *** i mean you have to open intake than tb than you can remove the injector rail.

Pics of the DIY.

BTW i bought injectors for 750 Rs. (3). though they are not same color but they are badly short in market and new are not available.

BTW Xulfiqar bhai i jumped FP and b+ but my pump (with COR) didnt turn on with ignition at on.

Now starting is first click

Faulty Injectors

[Vaqas1]

Replacement injectors.
I know different color means different output but sadly new are not available and 2nd hand are badly short in market.

[Xulfiqar]

your injectors are hanging because of dirt inside them, get them sonic cleaned.

for the FP pin to work you need to connect the FP wire (thin green wire) from the diagnostic port to the fuel pump live pin coming out from the Circuit opening relay. This wire is in the engine wiring harness by the ECU plugs along with the original rpm signal wire.

the FP also serves purpose to check circuit opening relay operation at the diagnosis port.

The B+ would be connected because it branches off from the injector positive wire. The E1 would also be connected as it is connected to the engine earth and shared by the ECU. All these wires are in the loom hence never cut, the FC, FP, IG-, AC1, ACT, SPD, ELS, B+ and B1 are cut because these are body loom wires. In very uncut wiring the original wiring plug would still be intact.

[Ghuncha]

your injectors are hanging because of dirt inside them, get them sonic cleaned.

for the FP pin to work you need to connect the FP wire (thin green wire) from the diagnostic port to the fuel pump live pin coming out from the Circuit opening relay. This wire is in the engine wiring harness by the ECU plugs along with the original rpm signal wire.

the FP also serves purpose to check circuit opening relay operation at the diagnosis port.

The B+ would be connected because it branches off from the injector positive wire. The E1 would also be connected as it is connected to the engine earth and shared by the ECU. All these wires are in the loom hence never cut, the FC, FP, IG-, AC1, ACT, SPD, ELS, B+ and B1 are cut because these are body loom wires. In very uncut wiring the original wiring plug would still be intact.

from where we can get our hands on ultrasonic cleaner and how much does it costs? is it the same small machine with a glass ornament on top used by opticians to clean contact lenses?

[Vaqas1]

Ultrasonic cleaning is available in Lahore. A guy nameed omer on pakwheels run that business. In Isb/Pindi hmm only better cleaning option is liqui Moly injector cleaner :p.

I think Omer charges around 2500 Rs.

But I took 3 hours to complete this injector replacement I will avoid to repeat it as much as i Can :p...

[Xulfiqar]

Ultrasonic cleaning is available in Lahore. A guy nameed omer on pakwheels run that business. In Isb/Pindi hmm only better cleaning option is liqui Moly injector cleaner :p.

I think Omer charges around 2500 Rs.

But I took 3 hours to complete this injector replacement I will avoid to repeat it as much as i Can :p...

removing and replacing injectors on this engine are not hard at all, try removing them on a BMW 318i - heavy cursing is required even after taking off the spider like inlet manifold top piece. All injector connectors are clipped into place by one giant plastic piece having 4 wire clips moulded in them.

[Vaqas1]

removing and replacing injectors on this engine are not hard at all, try removing them on a BMW 318i - heavy cursing is required even after taking off the spider like inlet manifold top piece. All injector connectors are clipped into place by one giant plastic piece having 4 wire clips moulded in them.

Well if i compare it with first gen 5AFE replacing injectors are bit hard plus in 80% humidity and around 38c :p...

BTW Xulfiqar bhai one thing i never disscused it with you is after upgrading engine do i have to upgrade its exhaust as well? Currently piping is 1.5 inch with one tube type resonator in the middle and muffler at back.. Muffler rattles a lot when i press accelerator.

Shown it to one guy he suggested that i should upgrade piping to 1.7 Inch.

Install one resinator in middle and one tube type resonator and one exhaust muffler at back. He says that tube type resonator also comes with 1.6 car stock.. So in total I will have 2 resonators and one exhaust muffler. my aim so gain better balance power and not noise but mostly these exhaust walas aim for sound

BTW my starting is back to where it should be

[zesti]

Hello friends,
I was quite busy in last few days and could not check the thread. OK I was not satisfied with my 5A-FE, had to push the accelerator. I knew it from first day that the accelerator cable has a joint in it. So replaced the cable last Sunday and wallah the world changed.....
One interesting thing I done, put a Tesla CNG kit (there's long interesting story to make it work, will share with you later). I have auto tranmission and on 55 cylinder it's giving around 135K local. There are some issues running on Petrol but for now it's running fine on CNG but I want it perfect on Petrol. My ECU wiring is uncut, need to check the sensor's. I have replaced my meter panel to fix RPM meter problem (previously it was 2.0D). There is no check engine light. Any help about getting it lit first.

[Vaqas1]

Hmm if you dont have check engine light in your meter you can use some other light available in your meter not used by anything else.

Or install a small bulb get positive of that bulb from battery positive and negative from W pin of ECU and your CEL will work..

[Vaqas1]

Got the exhaust work done.

The exhaust muffler is bought from Sinner its a twin tip toyota one.

Fitting of muffler is still not perfect and will be worked on later

[Xulfiqar]

The exhaust muffler looks terribly out of place - the pipes are way below the bumper cut off and way to short (this also causes a serious problem of exhaust sucking up back under the car and finally into the car too) - the key in exhausts is the tail pipe should be projecting from the last panel of the car.

To correctly place a muffler - use a jack and some spacers to support it - while the welder then correctly tacks the hangers to the muffler, finally get some nice pipes bent and shaped to correctly exit the bumper and cut them off downwards. The tips are not bad as they will do a good job of keeping the pipes clean.

btw - back in the day - I could buy genuine design twin pipe exhaust mufflers for 80 and 90 series corollas - they were made in Faisalabad, not usual two chamber design but were exact copies of the original design that allowed a very muted note on heavy acceleration and high rpm. They were twice the price of regular pakistani units. Dont remember the name - but for sure they were made in Faisalabad, Pakistan.

[Xulfiqar]

Well if i compare it with first gen 5AFE replacing injectors are bit hard plus in 80% humidity and around 38c :p...

BTW Xulfiqar bhai one thing i never disscused it with you is after upgrading engine do i have to upgrade its exhaust as well? Currently piping is 1.5 inch with one tube type resonator in the middle and muffler at back.. Muffler rattles a lot when i press accelerator.

Shown it to one guy he suggested that i should upgrade piping to 1.7 Inch.

Install one resinator in middle and one tube type resonator and one exhaust muffler at back. He says that tube type resonator also comes with 1.6 car stock.. So in total I will have 2 resonators and one exhaust muffler. my aim so gain better balance power and not noise but mostly these exhaust walas aim for sound

BTW my starting is back to where it should be

The piping should be 1 and 3/4 inch at least on this car whether 1.3 or 1.5 litre. The noise is because of the tube resonator not suited for your car. The original style resonator has a baffle type effect. and is oriented to be fit in one direction only.

[Xulfiqar]

Well if i compare it with first gen 5AFE replacing injectors are bit hard plus in 80% humidity and around 38c :p...

I will give you a workshop, industrial fans and all tools including limo pani (pepsi-coke etc) - remove and replace the injectors on the said BMW in less than 2 hours - lets see if you complain or plan to shoot the designer.

[Vaqas1]

The exhaust muffler looks terribly out of place - the pipes are way below the bumper cut off and way to short (this also causes a serious problem of exhaust sucking up back under the car and finally into the car too) - the key in exhausts is the tail pipe should be projecting from the last panel of the car.

To correctly place a muffler - use a jack and some spacers to support it - while the welder then correctly tacks the hangers to the muffler, finally get some nice pipes bent and shaped to correctly exit the bumper and cut them off downwards. The tips are not bad as they will do a good job of keeping the pipes clean.

btw - back in the day - I could buy genuine design twin pipe exhaust mufflers for 80 and 90 series corollas - they were made in Faisalabad, not usual two chamber design but were exact copies of the original design that allowed a very muted note on heavy acceleration and high rpm. They were twice the price of regular pakistani units. Dont remember the name - but for sure they were made in Faisalabad, Pakistan.

Yes I know muffler is out of place thats why I said it will be fixed soon :p...

This was installed for testing and it passed the test so i will be getting it properly fixed.

Local exhaust walas got those local made mufflers and very limited choice.
Didnt see any twin pipe ones with them :).

[Vaqas1]

The piping should be 1 and 3/4 inch at least on this car whether 1.3 or 1.5 litre. The noise is because of the tube resonator not suited for your car. The original style resonator has a baffle type effect. and is oriented to be fit in one direction only.

This is the resonator i got now. Rattle noise is gone.

[Vaqas1]

I will give you a workshop, industrial fans and all tools including limo pani (pepsi-coke etc) - remove and replace the injectors on the said BMW in less than 2 hours - lets see if you complain or plan to shoot the designer.

(H) I guess designer must have thought the injectors will work forever

[Xulfiqar]

Yes I know muffler is out of place thats why I said it will be fixed soon :p...

This was installed for testing and it passed the test so i will be getting it properly fixed.

Local exhaust walas got those local made mufflers and very limited choice.
Didnt see any twin pipe ones with them :).

There was only one old-fashioned exhaust place in Karachi which stocked that muffler brand, and I swear that guy knew exactly what he was doing - in his shop he had wire welders, hydraulic pipe benders, support tripods, pipe cutters etc. And in that shop alone I saw those mufflers and was really amazed by the workmanship. The suppliers also gave him one that was sliced lengthwise as a proof for customers to see how its made inside.

At the time when a regular muffler cost Rs 700/- those cost Rs 1600/- so you can guess the difference yourself.

[Vaqas1]

Ok I got the Exhaust tips fixed :).

BTW after installing this muffler i feel the torque of the car increased especially on high revs and on climb.

[ahsanonline]

congrats! double tip exhaust looks nice!

[ahsanonline]

since long i've suspected the TPS on my motor to be the wrong one. today got it confirmed. it only puts out 3.7volts at wot. cant set it further up or else IDL will stay open all the time. any idea where this sensor might've come from? i mean from which engine because this cant be from a 5AFE...

got to look for a replacement now....