a) Install a new sealing sleeve on the injector (if you filmed).
b) Apply a thin layer of fuel (lithol) to the new O-ring and install it on the injector.
c) Rotate the injectors and insert them into the fuel manifold.
d) Install (better stick it) four insulators and two spacers.
d) Install the injectors together with the fuel manifold onto the intake manifold. Gradually tighten the bolts securing the fuel manifold to the intake manifold.
4A-FE, 5A-FE, 7A-FE
3S-FE, 4S-FE
e) Make sure that the injectors rotate in their seats without sticking.
Note: If the injectors do not turn, the O-rings may be installed incorrectly. Replace the O-rings.
g) Install the injectors so that their connectors are on top.
c) Bolt the fuel manifold to the cylinder head.
- Tightening torque - 17 Nm
2. Connect the electrical connectors of the injectors.
4A-FE, 5A-FE, 7A-FE
1. Connect the fuel inlet hose to the fuel manifold: install the bypass bolt (with 2 new gaskets) and tighten it.
- Tightening torque - 29 Nm
2. Connect the fuel return line to the fuel pressure regulator.
3. (For serial engine version only) Install the upper intake manifold.
Install a new gasket and using a 6mm socket wrench, tighten the 3 bolts and 2 nuts in the sequence shown in the illustration.
- Tightening torque - 19 Nm
4. Connect the crankcase ventilation hoses.
5. Connect the manifold absolute pressure sensor hose.
6. (For serial engine version only) Install the upper intake manifold support.
a) Place a new gasket on the upper intake manifold flange with the tab on the gasket facing down.
b) Secure the intake manifold top post and engine transport hook (eye) with a bolt and nut.
- Tightening torque - 28 Nm
Note: Use a new bolt and a new nut.
c) Secure the air bypass tube and fuel inlet hose with a bolt (or 2 bolts).
7. Install the throttle body.
8. (5A-FE) Connect the hoses to the throttle body and the upper intake manifold cover.
9. (5A-FE) Install the air cleaner cover and air duct.
8. Connect the accelerator cable to the throttle body.
9. (Models with automatic transmission with serial engine version)
Connect the throttle valve control cable.
10. Install the air filter hose.
11. Fill the cooling system with coolant.
3S-FE, 4S-FE
1. Connect the vacuum hose to the fuel pressure regulator.
2. Install the two wire harness clamps to the brackets on the intake manifold.
3. Connect the fuel return hose to the fuel return pipe.
4. Connect the fuel inlet hose to the intake manifold.
a) Temporarily connect the fuel inlet hose and the fuel pressure damper using 2 new gaskets.
b) Tighten the vibration damper.
- Tightening torque - 34 Nm
5. Install the cylinder head cover (see section "Cylinder head").
6. Install intake manifold bracket #1 by tightening the two bolts.
- Tightening torque - 42 Nm
7. (Models with EGR system) Install the EGR valve and the EGR tube.
The original article is on the portal: ToyotaMan.ru
a) Install the new gasket, valve and pipe assembly using the bypass bolt and 2 nuts.
Tightening torque:
- nuts - 13 Nm
- bolts - 59 Nm
b) Connect the vacuum hose (1) to the EGR valve (from port E of the electro-pneumatic valve) and the EGR hose (2) (from pressure modulator).
8. Install the intake manifold bracket #2 and left engine lift bracket with the bolt and nut.
- Tightening torque - 42 Nm
9. Install the throttle body.
10. Connect the (-) wire to the negative terminal of the battery.