A) Install a new sealing sleeve on the injector (if filmed).
b) Apply a thin layer of fuel (lithol) on a new O-ring and install it on the injector.
V) Rotate the injectors and insert them into the fuel manifold.
G) Install (better stick it) four insulators and two spacers.
d) Install the injectors together with the fuel manifold on the intake manifold. Gradually tighten the fuel rail to intake manifold bolts.
4A-FE, 5A-FE, 7A-FE
3S-FE, 4S-FE
e) Make sure the injectors turn without sticking in their seats.
Note: If the nozzles do not turn, the O-rings may not be properly installed. Replace o-rings.
and) Install the injectors so that their connectors are on top.
h) 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 pipe to the fuel pressure regulator.
3. (Only for serial version of the engine) Install the intake manifold top.
Install a new gasket and use a 6mm socket wrench to 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 intake manifold absolute pressure sensor hose.
6. (Only for serial version of the engine) Install the upper intake manifold strut.
A) Lay a new gasket on top of the intake manifold flange with the tab on the gasket facing down.
b) Attach the upper intake manifold strut and transport hook (eye) engine bolt and nut.
- Tightening torque - 28 Nm
Note: Use a new bolt and a new nut.
V) Secure the air bypass tube and fuel inlet hose with the bolt (or 2 bolts).
7. Install the throttle body.
8. (5A-FE) Connect hoses to throttle body and intake manifold top cover.
9. (5A-FE) Install the air filter cover and air duct.
8. Connect the accelerator cable to the throttle body.
9. (Models with automatic transmission with a serial engine option)
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 tube.
4. Connect the fuel inlet hose to the intake manifold.
A) Temporarily connect the fuel inlet hose and fuel pressure oscillation 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 exhaust gas recirculation) Install the solenoid valve and EGR pipe.
A) Install a new gasket, valve and tube assembly using the bypass bolt and 2 nuts.
Torque:
- nuts - 13 Nm
- bolts - 59 Nm
b) Connect the vacuum hose to the EGR valve (1) (from port E of electropneumatic valve) and EGR hose (2) (from pressure modulator).
8. Install intake manifold bracket #2 and left engine lift bracket with bolt and nut.
- Tightening torque - 42 Nm
9. Install the throttle body.
10. Connect (-) negative battery cable.